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Mitsubishi 1992 3000GT, Service Manual

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Mitsubishi 1992 3000GT Service Manual Download Page 603

MANUAL TRANSAXLE 

   Specifications

MANUAL TRANSAXLE 

 

GENERAL SPECIFICATIONS

Items

Up to 1993 model

Model

From 1994 model

 engine

 (Turbo)

 (Turbo)

 transaxle floor shift

 

 transaxle floor shift

Sear ratio

 1st

 

 3.266

I

3rd

 1.103

 1.241

I

 4th

 

 0.918

I

Reduction ratio

6th

Reverse

Primary

0.589

3.076

3.153

1.375

Front differential

2.888

3.166

Transfer

0.814

0.958

Speedometer gear ratio (driven/drive)

Oil quantity 

 (qts.)  Transaxle

2.4 (2.5)

2.4 (2.5)

I

Transfer

 0.27 

 0.6 

LUBRICANTS

Items

Transmission oil

Transfer oil

Drive shaft oil seal lip

Transfer oil seal lip

Specified lubricants

Quantity 

 (qts.)

2.4 (2.5)

0.27 

 

Hypoid gear oil, SAE 

 or 

conforming to API classification GL-4

0.6 

 

As required

TSB Revision

Summary of Contents for 1992 3000GT

Page 1: ......

Page 2: ......

Page 3: ...hi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products...

Page 4: ...ying after painting remove the SRS components air bag module SRS diagnosis unit front impact sensors beforehand 3 Service or maintenance of any SRS component or SRS related component must be performed...

Page 5: ...ft Boots 52 Engine Coolant 51 Engine Oil 47 Engine Oil Filter 48 Evaporative Emission Control System 46 Exhaust System 60 Fuel Hoses 45 Fuel System Tank Pipe Line Connections and Fuel Tank Filler Tube...

Page 6: ...FERENCE VALUE Indicates the adjustment value prior to starting the work presented in order to facilitate assembly and adjustment procedures and so they can be com pleted in a shorter time CAUTION Indi...

Page 7: ...nit is indicated by sym bols output r input Input output Indicates a connector The broken line inc cates the same connec tor The connector symbol indicates the device side connector for an intermediat...

Page 8: ...s Omitted if The part designation number corresponds to the reassembly is possible in reverse order of disas number in the illustration to indicate disassembly sembly steps steps Classifications of Ma...

Page 9: ...andgfWboXcwnsctingbog 2 s mid v e OLxIlieEmr VeNc es wiU EPS 2 EenthenutbutdonatremoveK l FOG lJGl l RELAY coNnNulTY CHECX 0 0 indicates that there is continuity between the termi nals 0 0 indicates t...

Page 10: ...usDfv At wnes 2 45 2 55v 15 RdrigQsm rapanue SmsoOr 1 SaM Pm temosmun 2 77 I 0 1511 4 k y se c i nonnaOFF BOD 16 passewm w SmawPmtarmaM 25 f77 F Iv tsv NR 4ko I 1 7 p t I smxmtampcrmrre2 whmarc mdlt a...

Page 11: ...es for each trouble symptom will be found by means of this chart INSPECTION PROCEDURE FOR DIAGNOSTIC SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms classified in th...

Page 12: ...aution If resistance and continuity checks are performed on the wrong terminals damage to the vehicle wiring sensors ECU and or ohmmeter may occur Use care to prevent this 4 If the ohmmeter shows any...

Page 13: ...condition at each connector terminal Check trouble symptom Refer to Connector Inspection Service Points The connector position can be located in the wiring diagram in Vol _ ume 2 manual by means of t...

Page 14: ...arts of that circuit s Be sure to use the inspection proce dures provided for diagnostic trouble codes and trouble symptoms For temperature and or moisture conditions re lated intermittent malfunction...

Page 15: ...Others Line X 1992 models Driver Air Bag Passenger B 1993 models Manual Seat Belt A From 1994 Driver and Passenger Air models 1 Bag 1 D 3000GTFWD 11992 models Price class Convertible models W 3000GT...

Page 16: ...MRXML7M JA3BM64JClPY 1993 model ZllAMNPML7M JA3XD64BElNY 1992 model Zl lAMRPML7M JA3BN74KOPY 1993 model JA3XE74CClNY 1992 model Mitsubishi 3000GT 3 0 dm3 181 4 cu in Z15AMNGFL7M AWD DOHC MFI Turbo ZlG...

Page 17: ...Mitsubishi 3000GT AWD i 1 Engine displacement Hatch back 3 0 dm3 181 4 cu in DOHC MFI Con vertible 3 0 dm3 181 4 cuin DOHC MFI Turbo Con vertible T Models code ZllAMNPML7M ZllAMRPML7M VEHICLE INFORMA...

Page 18: ...y certification label is attached to the face of left door pillar 2 This label indicates the month and year of manufacture Gross Vehicle Weight Rating G V W R and Gross Axle Weight Rating G A W R fron...

Page 19: ...abel is attached to replacement parts for the body outer panel main components and the same data are stamped into replacement parts for the engine and the transaxle OOK621 00002280 Cautions regarding...

Page 20: ...axle ZOOFOOS3 ZOOFOO16 Manual transaxle cF5M33 Manual transaxle cW SMGl Up to 1993 models cWGMGl From 1994 models Fender Door 231FOO70 the illustration indicates left hand side outer Right hand side i...

Page 21: ...tached to the inner side of the part shown in the illustration The illustration indicates left hand side outer Right hand side is symmetrically opposite Liftgate 3ear bumper Target area A for original...

Page 22: ...ations H o o d 0 Sun visor l Glove box l SRS diagnosis unit l Steering wheel l Air bag module l Clock spring l Steering gear and linkage clamp 6 Store components removed from the SRS in a clean and dr...

Page 23: ...egative terminal is connected warm up the engine and allow it to idle for approximately ten minutes under the conditions described below in order to stabilize the engine control conditions and then ch...

Page 24: ...connection of the scan tool should always be made with the ignition switch in the OFF position 2 Always use a ROM pack that is appropriate for the vehicle ROM Pack Applicable Model 1 1 MB991423 1 1992...

Page 25: ...Manual transaxle vehicles may be towed on the front wheels provided the transaxle is in neutral and the drive line has not been damaged The steering wheel must be clamped in the straight ahead positio...

Page 26: ...stands 4 Never allow passengers to ride in a towed vehicle 5 State and local rules and regulations must be followed when towing a vehicle AWD Caution 1 If only the front wheels or only the rear wheel...

Page 27: ...Under the mid point of No 1 crossmember NOTE On vehicles with active aero system the front jacking point can be accessed by removing the center cover panel from the under cover Be sure to reinstall t...

Page 28: ...ns Approximate center of gravity Frame contact hoist twin post hoist or scissors jack emergency locati s EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack su...

Page 29: ...force REAR WHEEL MEASUREMENTS After placing the rear wheels on the brake tester follow the same procedures as for the front wheel measurements WHEEL BALANCE FRONT WHEEL MEASUREMENTS 1 Jack up the rea...

Page 30: ...ions GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS ZOOFOO15 I NOTE l 1 1992 model 3 4ws l 5 1995 model Hatchback l 2 l 7 1993 1996 model model 4 1994 model Hatchback l 6 1995 model Convertibl...

Page 31: ...d manual W6MGl 2 6 speed manual Fuel system Model No Type Automatic transaxle Fuel supply system F4A33 4 speed automatic Multiport fuel injection system cMFI system F4A33 4 speed automatic Multiport f...

Page 32: ...e used Standard bolt and nut tightening torque Bolt nominal diameter mm Pitch mm Head mark 4 Torque Nm ft lbs Head mark 7 Head mark 8 1 2 5 1 8 1 4 9 3 6 1 0 4 9 3 6 8 8 6 5 9 8 7 2 M8 1 25 12 8 7 22...

Page 33: ...t crank Starting system faulty 16 19 or cranks slowly ENGINE WILL NOT START OR HARD TO START CRANKS OK Symptom Engine will not start or hard to start Cranks OK Probable cause No fuel supply to injecto...

Page 34: ...30 GENERAL Master Troubleshooting ROUGH IDLE OR ENGINE STALLS rative emission purge control valve ENGINE HESITATES OR POOR ACCELERATION vaporative emission purge control valve l Vacuum hoses TSB Revis...

Page 35: ...orn or damaged POOR FUEL MILEAGE Symptom Probable cause Poor fuel mileage Fuel leak Reference page or remedy Repair as necessary 17 56 Repair as necessary Repair as necessary Repair as necessary Refer...

Page 36: ...cessively tightened steering gear box rack support cover 37A 20 Improper front wheel alignment 33A 6 Excessive turning resistance of tie rod ball joint 37A 7 Sticky flow control valve 37A 30 Bent rack...

Page 37: ...33A 10 ABNORMAL TIRE WEAR Symptom Probable cause Reference page Abnormal tire wear Improper front or rear wheel alignment 33A 6 34 5 25 Improper tire pressure 31 3 lmbalanced wheels c Loose wheel bear...

Page 38: ...turning resistance of lower arm ball 33A 11 joint Wheel bearing seizure Replace Broken or worn coil spring 33A 7 Bent front or rear axle drive shaft 26 12 Deformed lower arm 33A 10 STEERING WHEEL SHI...

Page 39: ...on results from grease deteriora tion which causes particles of pigment contained in grease to adhere to surfaces Heat discoloration will appear as a deep brown or purple Probable cause Excessive bear...

Page 40: ...assification SH ECII SH CD ECII SG ECII or SGKD EC11 For further details refer to LUBRICANTS SELECTION section Caution Test results submitted to EPA have shown that laboratory animals develop skin can...

Page 41: ...mixture of 10 ethanol grain alcohol and 90 unleaded gasoline may be used in your car If driveability problems are experienced as a result of using gasohol it is recommended that the car be operated on...

Page 42: ...Description Metric measure U S measure Engine oil Crankcase 4 0 dm3 4 2 qts Oil filter 0 3 dm3 32 qt Oil cooler Turbo 0 3 dm3 32 qt Total Non Turbo 4 3 dm3 4 5 qts Total Turbo 4 6 dms 4 9 qts Cooling...

Page 43: ...are not available an API classification SH ECII SH CD ECII SG EC11 or SG CD EC11 can be used Oil Viscosity The SAE grade number indicates the viscosity of the oil A proper SAE grade number should be s...

Page 44: ...erating temperature is 15 C 5 F when the measured specific gravity is 1 058 at the coolant temperature of 20 C 68 F Caution 1 If the concentration of the coolant is below 30 the anti corrosion propert...

Page 45: ...Fuel hoses Air cleaner element Evaporative emission con trol system except evapo rative emission canister Sparks plugs Ignition cables Service to be Kilometers in thousands 24 48 72 96 120 144 168 per...

Page 46: ...The maintenance items should be performed according to the following table VO 3 5 9 10 t 14 t 1Mileage intervals kilometers in thousands Miles in thousands Severe usage conditions Maintenance Service...

Page 47: ...ace except platinum plugs X X X platinum plugs only X Replace Every 5 years or X Ignition cables NOTE I Except for Federal i GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE 10 General maint...

Page 48: ...ands No Maintenance Service to be Miles in thousands Severe usage conditions Item performed ii i 60 75 90 105 96 120 144 168 A B c 1 I 3 Air cleaner Replace at element x x x x x x xx 5 Spark plugs Rep...

Page 49: ...eplace it with a new one Non Turbo 1 Disconnect the volume air flow sensor connector 2 Remove the air intake hose from the volume air flow sen sor 3 Unclamp the air cleaner cover 4 Remove the air clea...

Page 50: ...e properly to assure proper engine performance and emission control Therefore they should be replaced periodically with new ones Spark plug NGK PFRGJ 11 NIPPON DENS0 PK20PRPll Spark plug gap 1 0 1 1 m...

Page 51: ...0 77 132 Deflection mm in 4 0 5 5 16 22 Reference value Tension N Ibs 250 500 55 l 10 Deflection mm in 9 5 13 5 37 53 Reference value Vehicle with air conditioning 1 Items I Specification I 1 For gene...

Page 52: ...strongly recommended for use on this vehicle Oil Filter Part No MITSUBISHI Genuine Parts MD136790 or equivalent Any replacement oil filter should be installed in accordance with the oil filter manufac...

Page 53: ...re reaches the usual temper ature 70 80 C 160 18O F 2 Place vehicle on level floor 3 Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid then p...

Page 54: ...ence of contamination Replenish with new fluid after the cause of any contamination has been corrected 1 Remove drain plug at transaxle case bottom to let fluid drain 2 Place a drain container with la...

Page 55: ...e the radiator cap to discharge coolant Remove the reservoir tank and discharge coolant When coolant has been discharged pour water through the filler port to flush coolant passage Coat the threads of...

Page 56: ...aulty installation casing twisting or interference with wheel tire or chassis 17 BALL JOINT AND STEERING LINKAGE SEALS Inspect for grease leaks and damage 1 These components which are permanently lubr...

Page 57: ...at the system is functioning properly 2 SRS COMPONENTS VISUAL CHECK 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 se...

Page 58: ...ly if a front impact sensor is not installed properly which could result in serious injury or death to the vehicle s driver and passenger 3 Check wiring harness for front impact sensor for binds conne...

Page 59: ...odels Ring gear Rotor Screw Caution label LJ Driver s side mote control b itch radio remote control switch To air bag module To cruis cvitch From 1994 models SRS diagnosis Ring gear Rotor Screw Flat c...

Page 60: ...le from steering wheel Refer to GROUP 52Ei3 Air Bag Module and Clock Spring C a u t i o n When disconnecting the air bag module clock spring connector take care not to apply excessive force to it 2 Ch...

Page 61: ...91 Conli From 1994 models Driver s side Inflator case Passenger s side 3 Check hooks and connectors for damage terminals defor mities and harness for binds 4 Check air bag inflator case for dents crac...

Page 62: ...Check clock spring connectors and protective tube for damage and terminals for deformities 10 Visually check the clock spring case and the gears for damage 11 Align the mating mark and NEUTRAL positi...

Page 63: ...he above components is not installed properly which could result in serious injury or death to the vehicle s driver and pas senger 2 4 Front Wiring Harness and Body Wiring Harness i L 236FOO19 1 Check...

Page 64: ...ON OF MUFFLER PIPINGS AND CONVERTER HEAT SHIELDS Check and service as required d 1 Check for holes and gas leaks due to damage corrqsion etc 2 Check the joints and connections for looseness and gas le...

Page 65: ...ded brand Sealing between tempered glass and weatherstrip Sealing between body flange and weatherstrip Sealing between laminated glass and weatherstrip 3M ATD Part No 8513 or equivalent 3M ATD Part No...

Page 66: ...e 3M ATD Part No 8155 or equivalent ANAEROBIC FAST BONDING ADHESIVE Application Recommended brand Fixing of bolts and screws 3M Stud locking Part No 4170 or equivalent l Tightening of drive gear to di...

Page 67: ...INE ASSEMBLY 18 TIMING BELT 31 ENGINE OIL COOLER m 36 TROUBLESHOOTING m 6 Li OIL PAN AND OIL SCREEN 23 ON VEHICLE SERVICE 7 Basic Idle Speed Adjustment Refer to GROUP 13A Compression Pressure Check 14...

Page 68: ...e V type DOHC Number of cylinders 6 Bore mm in 91 l 3 587 Stroke mm in 76 0 2 992 Turbo V type DOHC 6 91 l 3 587 76 0 2 992 Piston displacement cc cu in 2 972 181 4 2 972 181 4 SERVICE SPECIFICATIONS...

Page 69: ...or Vehicle without air Inspection 4 0 5 5 16 22 deflection conditioning mm in New belt 3 5 4 0 14 16 Reference value Used belt 4 0 5 0 l6 20 For generator and air conditioning Inspection 4 0 5 5 16 22...

Page 70: ...before ser vice MB991 502 MB991502 All models Scan tool Idle speed check MUT II ROM pack MD998051 MD998051 01 Loosening and tightening of cylinder head bolt Cylinder head bolt wrench MD998727 General...

Page 71: ...B MB990998 Used if the crankshaft needs to be rotated to at Q tach the timing belt etc when the piston and Crankshaft connecting rod assembly is assembled wrench SOHC Use only the large nut included i...

Page 72: ...igh Noisy valves Oil relief valve stuck opened Excessive bearing clearance Oil relief valve stuck closed Incorrect lash adjuster Repair relief valve Replace bearings Repair relief valve Replace lash a...

Page 73: ...midway between the pulleys as shown in the illustration check the belt tension for standard value Or apply a force of 98 N 22 Ibs to the belt to check the deflection for standard value Standard value...

Page 74: ...ning 1 Use straight handle box wrench to loosen tension pulley fixing nut 2 Adjust belt deflection with adjusting bolt 3 Use straight handle box wrench to tighten fixing nut 4 Run the engine one time...

Page 75: ...TE The engine speed indicated is a third of actual speed In other words the reading of the tachometer times 3 is actual speed 6 Turn OFF the ignition switch 7 Remove the water proof female connector f...

Page 76: ...ion connector blue and connect a tachometer to the paper clip NOTE Do not use the scan tool If tested with the scan tool connected to the data link connector the ignition timing will not be the basic...

Page 77: ...P ll 9 3 Set a timing light 4 Using a jumper wire ground the ignition timing adjusting terminal 5 Start the engine and let it idle 6 Check the ignition timing is the standard value if not adjust Stan...

Page 78: ...the CO tester and HC tester 6 Check the CO concentration and HC concentration with the engine at idle Standard value CO concentration 0 5 or less HC concentration 100 ppm or less 7 If the standard va...

Page 79: ...he data link connector white NOTE For the tachometer setting procedure refer to P ll 9 4 Start the engine 5 Open the throttle valve until the dashpot rod makes a full stroke 6 Close the throttle valve...

Page 80: ...owel Caution 1 When you crank the engine keep away from the spark plug mounting holes 2 If a compression measurement is performed with wa ter oil fuel etc in the cylinder due to the cracks in the cyli...

Page 81: ...ion of the crankshaft position sensor connector MANIFOLD VACUUM CHECK 1 The vehicle should be repaired as follows before the inspection l Engine coolant temperature 80 95 C 176 203 F l Lights electric...

Page 82: ...conds and then decelerate it to the idling speed slowly in 30 seconds NOTE 1 When the vehicle is parked on a slope for a long period the oil in the lash adjuster will decrease When the engine is start...

Page 83: ...shed down Therefore turn the crankshaft to keep the piston position down In addition the rocker arm located at the valve lifted by the cam cannot be removed Therefore turn the crankshaft to keep the c...

Page 84: ...23 Transaxle Assembly l Front Exhaust Pipe Installation Refer to GROUP 15 Exhaust Pipe and Main Muffler l Air Hose and Air Pipe Turbo Installation Refer to GROUP 14 Charge Air Cooler l Hood Installati...

Page 85: ...ensor connector 2 26 Engine coolant temperature switch connector Air conditioning 2 27 Engine coolant temperature sensor connector 28 Engine coolant temperature gauge unit connector 29 Condenser conne...

Page 86: ...e mount bracket installation bolt use a chain block or similar arrangement to suspend the engine assembly to the extent that there is no looseness of the chain C ENGINE ASSEMBLY REMOVAL After checking...

Page 87: ...installation Refer to GROUP 16 Cam Position Sensor and Crankshaft Position Sensor l Intake Manifold Installation Refer to GROUP 15 Intake Manifold l Timing Belt Installation Refer to P li 31 l Accele...

Page 88: ...ATION SERVICE POINTS A CAMSHAFT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the oil seal lip 2 Using the special tool insert the oil seal B CAMSHAFT SPROCKET INSTALLATION Using a wre...

Page 89: ...pe Removal and Installation Refer to GROUP 15 Exhaust Pipe and Main Muffler l Transfer Assembly Removal and Installation cAWD Refer to GROUP 22 Transfer Assembly 19 Nm 1A fi Ihs w n l hs p I I 6 Nm A...

Page 90: ..._ i _I i Q L zL0583 j 1 ri o o z REMOVAL SERVICE POINT dA OIL PAN REMOVAL After removing the bolts use the special tool and a brass bar to remove the oil pan from the cylinder block d Caution Remove t...

Page 91: ...h a f t Eder Ypy s yp4 J G 1 Ah I Oil is I ZOlNOOld i A A g kshaft front oil seal REMOVAL SERVICE POINT dAbCRANKSHAFT FRONT OIL SEAL REMOVAL 1 Make a notch in the oil seal lip section with a knife etc...

Page 92: ...eal Camshaft 73 77 Nm 53 56 ft lbs R E M O V A L S E R V I C E POINTS A FLYWHEEL REMOVAL Stop the crankshaft pulley from turning and remove the fly wheel Caution Use only the specified special tools o...

Page 93: ...eal 11 27 INSTALLATION SERVICE POINT A CRANKSHAFT REAR OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the oil seal lip and then insert P I i 1 Oil s l ZOlM0031 2 Tap the oil seal into t...

Page 94: ...Manifold Installation Refer to GROUP 15 Air Intake Manifold l Engine Coolant Supplying Refer to GROUP 00 Maintenance Service l Accelerator Cable Adjustment Refer to GROUP 13F Engine Control l Engine...

Page 95: ...tion mark for the engine 2 Lay the cylinder head gasket on the cylinder block with the identification mark at the front top B CYLINDER HEAD ASSEMBLY INSTALLATION 1 Use a scraper to clean the gasket su...

Page 96: ...LLATION Tighten the rocker cover bolts in the order shown in the illustra tion NOTE I Only No 5 bolt in the rear bank differs from other bolts in length Rear bank No 5 bolt 20 mm 79 in Except rear ban...

Page 97: ...tion l Front Under Cover Panel Installation Vehicle with Active Aero l Cruise Control Link Assembly Installation Vehicle with Cruise Control Refer to GROUP 13G Cruise Control l Engine Adjustment Refer...

Page 98: ...of rotation so it may be reassembled in the same direction if it is to be reused 3 Loosen the center bolt on the tensioner pulley to remove the timing belt Caution Water or oil on the belt shortens i...

Page 99: ...ing marks on the camshaft sprockets for intake and exhaust valves are not within the range A in the illustration at left If the timing mark is within range A turn the camshaft sprocket to move the tim...

Page 100: ...the tensioner pulley so that its pin holes are located above the center bolt Then press the tensioner pulley against the timing belt and at the same time temporarily tighten the center bolt 4 Check th...

Page 101: ...are aligned properly Dl TIMING BELT LOWER COVER INSTALLATION Since the mounting bolts of timing cover are different in size depending on location insert them with care FE4 ENGINE SUPPORT BRACKET INSTA...

Page 102: ...ine oil return hose 4W 4 Engine oil return tube 5 Engine oil cooler REMOVAL SERVICE POINTS dAbENGINE OIL FEED HOSE ENGINE OIL RETURN TUBE REMOVAL Caution Be sure to hold the weld nut of the oil cooler...

Page 103: ...CONTROL TYPE CARBURETOR 13B CONVENTIONAL TYPE CARBURETOR 13c VARIABLE VENTURI TYPE CARBURETOR 13D DIESEL FUEL 13E FUEL SUPPLY 13F CRUISE CONTROL SYSTEM Refer to GROUP 17 TRACTION CONTROL SYSTEful t3l...

Page 104: ...13 2...

Page 105: ...268 240 270 279 200 279 211 211 247 263 264 229 230 Induction Control Valve Position Sensor 242 Injectors 257 Intake Air Temperature Sensor 215 Knock Sensor 237 Manifold Differential Pressure MDP Sen...

Page 106: ...Turbocharger Waste Gate Solenoid 169 Variable Induction Control Motor DC Motor 174 Vehicle Speed Sensor Electrical Speedometer Type 119 Mechanical Speedometer Type 117 Volume Air Flow Sensor 85 ON VE...

Page 107: ...r posItIon II Intake air temp sensor c From fuel tank w _ _ I 1 2 3 4k EVAP canister Electric load switch I i 6 7 8 module 27FU1323 NOTE 1 EVAP purge solenoid 2 lniector 3 ldie air control motor 4 Var...

Page 108: ...valve position sensor Throttle position sensor Closed throttle position switch m lntake air temp sensor Volume air flow sensor Barometric pressure sensor m I 6 7 t Z7FU1325 NOTE 1 EVAP purge solenoid...

Page 109: ...trol valve posrtron sensor I nrottle positron sensor Closed tnrottle poslkon swatch Intake arr temp sensor NOTE J Z7FU1462 1 f AP purge solenoid 2 Injector 3 EGR plnnni 4 mIII IY 4 Idle air control mo...

Page 110: ...tion sensor _ Throttle position sensor Closed throttle cosition switch module NOTE l l EVAP purge solenoid 2 Injector 3 EGR solenoid 4 Idle air control motor 5 Variable induction contorl motor 6 Heate...

Page 111: ...ntrol NOTE 1 injector 2 EGR solenoid 3 IAC motor 4 Fuel pressure solenoid 5 Evaporative emission purge solenoid 6 Turbocharger waste gate solenoid 7 AC compressor clutch relay 8 Fuel pump relay 9 Igni...

Page 112: ...motet Engine ContrOl nlcd b 27FU1463 NOTE 1 Injector 2 EGR solenoid 3 Evaporative emission purge solenoid 4 IAC motor 5 Fuel pressure solenoid 6 Turbocharger waste gate solenoid 7 AK compressor clutch...

Page 113: ...models EGR IAC motor ii Intake air temperature senso 1 1 1 1 C shaftposition sensor I FlW NC switch _ P S pressure switch c Vehicle speed sensqr _ T mohle lqnition coil Iqnition cower transistor e Ch...

Page 114: ...SPECIFICATIONS GENERAL SPECIFICATIONS California Non Turbo emperature sensor c emiconductor type NOTE l l 1992 models l 2 1993 models 1 1994 and 1995 models E Except 1992 models From 1996 models Up t...

Page 115: ...oid BDL360 Direct current motor type ON OFF type solenoid valve 4 Duty cycle type solenoid valve 5 EGR solenoid Duty cycle type solenoid valve California Non Turbo Turbo Federal Non Turbo From 1996 mo...

Page 116: ...ERVICE SPECIFICATIONS e speed when air conditi gine coolant temperatu OTE Up to 1992 models 2 From 1993 models SEALANT Items Specified sealant Engine coolant temperature sensor threaded portion 3M NUT...

Page 117: ...TIPORT FUEL INJECTION Special Tools SPECIAL TOOLS tester cMUT Reading diagnostic trouble code l MFI system inspection Test harness set Basic idle speed adjustment l Inspection by oscilloscop TSB Revis...

Page 118: ...13A 14 MULTIPORT FUEL INJECTION Special Tools TSB Revision...

Page 119: ...If the signals are normal judge the sensor input actuator control as normal and proceed to check the input output signals of the next check item 5 Inspection of MFI system component harness l If the e...

Page 120: ...s for the particular connector is not available the use of the Test Harness Set MB991348 which can be connected directly between the terminals is recommended l When checking the terminal voltage with...

Page 121: ...off the lamp goes out Even if the ignition switch is turned on again the lamp does not come on until the irregularity is detected Here immediately after the ignition switch is turned on the check eng...

Page 122: ...13A 18 MULTIPORT FUEL INJECTION Troubleshooting ITEMS INDICATED BY THE CHECK ENGINE MALFUNCTION INDICATOR LAMP From 1996 models 2 sensor circuit malfunctio dle control system ma TSB Revision...

Page 123: ...tch is turned on the lamp illuminates for about 5 seconds and then goes out 2 If the lamp does not illuminate check for open circuit in harness blown fuse and blown bulb ON BOARD DIAGNOSTIC Up to 1995...

Page 124: ...also output when the ignition timing adjustment terminal is grounded to adjust the igni tion timing but this does not show any abnormality DIAGNOSTIC CHART FAULT TREE Code No Output signal pattern Di...

Page 125: ...nmn If harness and connector are normal replace barometric L pressure sensor assembly v12Ao107 31 nnrLn Knock sensor l Harness and connector Retained If harness and connector are normal replace knock...

Page 126: ...ss and connector I Retained omia model from 1994 lts z SenSor l Injectors Replace if defective s12Ao105 l Intake air leaks Acablefromtransaxlecontrolmod l Harness and connector Retained ule for transm...

Page 127: ...eed is approx 1 900 2 200 r min l Vehicle is moving at constant speed on a flat level road surface Set Conditions The oxygen sensor output voltage does not cross specified voltage for specified second...

Page 128: ...ck l Engine control module failed l Ignition switch ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts Set Conditions l Sensor output voltage is...

Page 129: ...check l Ignition switch ON l Engine spped is approx 50 r min or more Set conditions l Ohe sensor output voltage increases from 1 6 V or less corresponding to an engine coolant temperature of 40 C 104...

Page 130: ...50 r min or more supply 4 seconds Set conditions after a problem is detected After the Sensor output voltage does not change for 4 seconds no pulse signal input Range of check l Ignition switch ON l E...

Page 131: ...ration of the cylinder block Switches the ignition l Open or shorted knock sensor into a voltage and outputs it If there is a malfunction of the timing from ignition tim circuit or loose connector kno...

Page 132: ...at constant speed on a flat level road surface tput voltage does not cross specified voltage xygen sensor deteriorated pen or shorted oxygen l Incorrect fuel pressure l Injector failed l Engine contro...

Page 133: ...ied out two times in succession a problem is detected after each operation Background l Ignition power transistor unit converts ON OFF variation of the ignition coil to the pulse signal Ignition signa...

Page 134: ...after deceleration finished Set Conditions ntrol module failed heated oxygen sensor rear output voltage is 0 1 V or heated oxygen sensor front output voltage is 0 5 V or ve conditions continue for a c...

Page 135: ...starting of the engine are carried out four times in succession a problem is detected after each operation Fault ID Title 69 cl994 and Right Bank Heated Oxygen Sensor ater Califor rear nia model Effe...

Page 136: ...switch is set to OFF Camshaft position sensor 1 Fuel injected into the cylinders in the order l 2 3 4 5 6 with irregular timing Provided that no No 1 cylinder top dead center position has been detect...

Page 137: ...stment is results can be read out with a scan tool grounded Moreover since memorization of the diagnostic Therefore it is not a malfunction that the code trouble codes is backed up directly by the bat...

Page 138: ...han 10 seconds 3 Perform test drives under the following conditions 1 On vehicles with automatic transmission set selector lever in D range overdrive switch ON Power Economy changeover switch in P ran...

Page 139: ...nk 1 Sensor 1 If harness and connector are normal replace Right bank 02 sensor front PO135 PO136 PO141 PO150 O2 Sensor Heater Circuit Mal l Harness and connector Retained function Bank 1 Sensor 1 l Ri...

Page 140: ...pressure sensor Exhaust Gas Recirculation l Harness and connector Retained Solenoid Malfunction l EGR solenoid Warm Up Catalyst Efficiency l Exhaust manifold Retained Below Threshold Bank 1 Replace t...

Page 141: ...tained Solenoid Malfunction l Turbocharger waste gate solenoid P1105 Fuel Pressure Solenoid l Harness and connector Retained Malfunction l Fuel pressure solenoid P1300 P1300 Ignition Timing Adjustment...

Page 142: ...ttery voltage is 8 V or more Set Conditions l Sensor output voltage is 4 5 V or more corresponding to a barometric pressure of 114 kPa 33 7 in Hg or more for 4 seconds or l Sensor output voltage is 0...

Page 143: ...6 V or more for 5 minutes Range of check l Engine coolant temperature is 20 68 F or more when the engine is started l Intake air temperature is 20 C 68 F or more when the engine is started Set conditi...

Page 144: ...t leaner and richer circuit in oxygen sensor and checks the response speed of oxygen sensor In addition the engine control module also checks for an open circuit in the oxygen sensor e control module...

Page 145: ...p control of the air fuel ratio The oxygen sensor output line is open circuit 1 DTC No L po155 Oxygen Sensor Heater Circuit Malfunction Probable causes Bank 2 Sensor 1 Background l Open or shorted oxy...

Page 146: ...or failed l Engine control module failed ntake air temperature sensor etric pressure sensor l DTC No Title PO201 PO206 Injector Circuit Malfunction Cylinder l Cylinder 6 Background l A surge voltage i...

Page 147: ...t voltage knock sensor peak voltage at each l 2 revolution of the crankshaft is less than 0 06 V for 200 times in succession Probable causes l Knock sensor failed l Open or shorted knock sensor circui...

Page 148: ...ed EGR solenoid the solenoid is ON and OFF Range of Check Set Conditions 0 No surge voltage is detected even when the EGR solenoid is turned off circuit or loose connector 0 Engine control module fail...

Page 149: ...oid has switched from OFF to ON current or loose connector does not flow to the coil for 4 seconds l Engine control module failed DTC No Title PO500 Vehicle Speed Sensor Malfunction Background l The v...

Page 150: ...f Check Set Conditions l The park neutral position switch failure signal is input to the engine control module l Park neutral position switch failed l Open or shorted park neutral position switch circ...

Page 151: ...on timing adjusting signal l If there is a short circuit in the line between the engine control module and the ignition wire circuit is shorted to the timing adjustment terminal the line voltage will...

Page 152: ...d l The transaxle control module monitors the torque converter clutch solenoid shift control solenoid and pressure control solenoid l When some one of these solenoids failed the transaxle control modu...

Page 153: ...position sensor Provided that no No 1 cylinder top dead center position has been detected since the ignition switch was placed in the ON position 2 Fuel cut 4 seconds after a failure was detected Prov...

Page 154: ...harness of MUT II to connect MUT II to 1993 and earlier models 2 Turn the ignition switch to ON 3 Take a reading of the diagnostic output 4 Repair the problem location referring to the diagnostic char...

Page 155: ...ck engine malfunction indicator lamp is used Typical blinking made while diagnostic trouble code is output In case of diagnostic trouble code No 24 1 5 second 0 5 second 0 5 second Ught comes on Light...

Page 156: ...ensor Intake air temperature sensor 3 3 1 1 1 1 72 200 2 13 11 85 21 2 2 5 aa 215 2 gnltion switch ST and Park Neutral EGR solenoid California Non Turbo Turbo Federal Non Turbo From 1996 Variable indu...

Page 157: ...or Non Turbo I4 4 16 6 133 242 2 Heated oxygen sensor I I I I I I I I 137 247 2 Injectors I 2 2 I 2 2 I 1 11 I 11 l I I 1 1 l44 257 2 Idle air control motor stepper motor type j I 1 9 7 I I 153 26 3 I...

Page 158: ...lay in response of the vehicle speed engine speed that occurs when the accelerator pedal is depressed in order to accelerate from the speed at which the vehicle is now traveling or a temporary drop in...

Page 159: ...he inspection and adjustment procedures set the vehicle in the following conditions l Engine coolant temperature 80 to 95 C 176 to 203 F l Lights electric cooling fan accessories OFF l Transaxle Neutr...

Page 160: ...throttle valve Refer to P 13A 57 3 The tachometer should read l 3 of the actual engine speed This means that the actual engine speed is the tachometer reading multiplied by 3 8 If the basic idle spee...

Page 161: ...the deposit cannot be removed from the throttle valve repeat steps 4 and 5 7 Disconnect the plug from the inlet of the bypass passage 8 Install the air intake hose 9 Use a scan tool to erase the diag...

Page 162: ...is turned OFF continuity between terminals 3 and 4 disappears Then tighten the throttle position sensor mounting bolt securely 7 If not using the scan tool proceed as follows a Disconnect the throttl...

Page 163: ...S by turning it counterclock wise to fully close the throttle valve 4 Tighten the fixed SAS slowly to find a point at which it contacts the throttle lever where the throttle valve starts opening From...

Page 164: ...le position sensor with built in closed throttle C position switch B Turbocharger waste gate solenoid Turbo U X Variable induction control motor DC motor with J built in induction control valve positi...

Page 165: ...NJECTION _ On Vehicle Inspection of MFI Components 13A 61 Volume air flow sensor with built in intake air Fro 19 models Mechanical Speedometer Type Vehicle speed sensor reed switch I 27FU1004 Y68FOOll...

Page 166: ...ORT On Vehicle Inspection of MFI FUEL INJECTION ComDonents Variable induction control motor fi DC motor with built in induction Injector Idle air control control valG position sensor Z7FUO802 t7FU0803...

Page 167: ...hicle Inspection of MFI FUEL INJECTION Components 1349 63 Check engine malfunction indicator lamp 1 z68FOOH and diagnostic test mode control terminal ZlBFO292 From 1994 models control terminal ZlEFC49...

Page 168: ...tuator test function If any abnormality is found check the body harness corn ponents etc and repair as necessary iii 2 After repair check again with the scan tool to make sure that the input and outpu...

Page 169: ...attery power is supplied to the engine control module the injector the volume air flow sensor etc l When the ignition switch is turned on the battery voltage is applied from the ignition switch to the...

Page 170: ...the harness module harness side connector Ignition switch 62 201 Lo227 age of the MFI relay l MFI relay connector Discon A Harness side connector Engine control module con nector Disconnected Check f...

Page 171: ...ltage at Voltage at terminal 4 terminal 5 I 1 Connected 1 B 1 B I 1 Disconnected 1 ov I ov I 4 Using jumper wires connect terminal 9 of MFI relay to battery terminal and terminal 6 of MFI relay to bat...

Page 172: ...CH IG From 1994 models Engine control module 16FO292 1 bv 7FUO927 OPERATION Refer to P l3A 65 INSPECTION Refer to P l3A 65 Battery MFI relay 4 3 2 0 0 Ignition 1 8 6 itch IG A Equipment side connector...

Page 173: ...ess side connector Z6AF0050 A Harness side connector Pleasure power voltage to the ac tuator l MFI relay connector Con nected l Engine control module con I Inectar Connected Engine cranking 8 V or hig...

Page 174: ...mper wire to battery terminal measure the voltage at terminal 1 of the MFI relay Jumper wire Voltage Connected B Disconnected OV 5 Using jumper wires connect terminal 8 of MFI relay to battery termina...

Page 175: ...OPERATION Grounds the engine control module TROUBLESHOOTING HINTS If the ground wire of the engine control module is not connected securely to ground the module will not operate correctly HARNESS INS...

Page 176: ...nnector Z7FUO952 Engine control module connector 27FUO653 7Fu1574 OPERATION l Drives the fuel pump during cranking and engine operation l When the ignition switch is set to START current flows from th...

Page 177: ...ers to feel pulsation pump Check is made for indicating fuel flow above two conditions Listen to pump operat Operating sound ing sound near fuel tank is heard HARNESS INSPECTION mu I F i pum check ter...

Page 178: ...epair the harness Cl Measure the Dower SUDDIV volt age of the MF I relay l MFI relay connector Discon nected l Ignition switch START when ir the A9 checked harness l Ignition switch ON when A3 Ignitio...

Page 179: ...13A 75 I i Check for an open circuit or a short circuit to ground between the MFI relay and the fuel pump l MFI relay connector Discon nected l Fuel pump connector Dis A connected Repair the harness A...

Page 180: ...e control module connector i7FU06 53 7FU1575 OPERATION l The fuel pump is driven when the engine is cranking and while the engine is running l When the engine is cranking and while the engine is runni...

Page 181: ...or Dis connected Repair the harness 82 Ground B Harness side connector u 4 Z7FUO954 Y la l L I3 E n 7 C Check for continuity between the fuel pump and the checking termi nal l Connector Disconnected Z...

Page 182: ...I relay and the engine con trol module MFI relay connector Dacon netted l Engine control module con nector Disconnected Repair the harness AS 8 Check for an open circuit or a short circuit to ground b...

Page 183: ...MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Components 13A 79 FUEL PUMP Turbo Fuel pump connector j 1 I i 1 w I 203kxl04 TSB vision _ 1...

Page 184: ...L 7 2 Fuel t l I M pump D Fuel pump 2 Z5ElAO03 6 c connector Y Engine control module pikq 1 Fuel pump check terminal B Equipment side connector B Harness side connector 13A 80 MULTIPORT On Vehicle Ins...

Page 185: ...l pump through the resistor If the amount of inlet air is large the engine load is high the engine control module turns off the power transistor to send drive power directly to the fuel pump without p...

Page 186: ...fuel pump con nector Disconnected l Fuel pump connector Dis connected Repair the har ness Cl D2 I iD2 E2j short circuit to ground beheen the fuel pump relay II and the en Engine control module con ne...

Page 187: ...rol module con nector Disconnected i Repair the harness A7 8 Check for continuity between the MFI relay and the fuel pump relay II II l MFI relay connector Discon nected l Fuel Dumb relav II connector...

Page 188: ...ery 3 With the jumper wire connected to and disconnected from the negative terminal of the battery check the continuity between terminals 2 and 5 of fuel pump relay II and between terminals 4 and 5 of...

Page 189: ...s a pulse signal as it repeatedly opens and closes between the 5 V voltage supplied from the engine control module and ground TROUBLESHOOTING HINTS Hint 1 If the engine stalls occasionally crank the e...

Page 190: ...creases with racing NOTE When the vehicle is new within initial operation of about 500 km 300 miles the volume air flow sensor output frequency may be about 10 higher Volume Air Flow Sensor Reset Sign...

Page 191: ...ay or check the control relay Connector Disconnected Ignition switch ON l 3 A Harness side connector 27FUO657 ml Engine control A Harness side q rls zde har connector r Z7FUO745 Check for continuity o...

Page 192: ...n the input signal l The 5 V power in the engine control module is supplied via a resistor in the module to the intake air temperature sensor Via the sensor which is a kind of resistor it is grounded...

Page 193: ...erature engine running At 0 C 32 F 0 C At 20 C 68 F 20 C At 40 C 104 F 40 C At 80 C 176 F 80 C HARNESS INSPECTION v T Check for continuity of the ground circuit l Connector Disconnected 0 2 Repair the...

Page 194: ...ponents 3 Measure resistance while heating the sensor using a hair drier Temperature C OF Higher Resistance kL2 Smaller 4 If resistance does not decrease as heat increases or the resistance remains un...

Page 195: ...nector l The barometric pressure sensor converts the barometric pressure into a voltage and inputs it to the engine control module which then corrects the fuel injection rate etc based on the input si...

Page 196: ...h ON Altitude Standard value At 0 m 0 ft 101 kPa 760 mmHg At 600 m 1 969 ft 95 kPa 710 mmHg At 1 200 m 3 937 ft 88 kPa 660 mmHg At 1 800 m 5 906 ft 81 kPa 610 mmHg A Harness side Z7FUO657 Check for co...

Page 197: ...rol module is supplied via a resistor in the module to the engine coolant temperature sensor Through the sensor which is a kind of resistor it is grounded in the engine control module The engine coola...

Page 198: ...At 20 C 4 F 20 C temperature engine operating At 0 C 32 F 0 C At 20 C 68 F 20 C At 40 C 104 F 40 C At 80 C 176 F 80 C HARNESS INSPECTION A Harness side 27FlJO668 J 2 A Harness side connector 1 4 27FlJ...

Page 199: ...in hot water check resistance Temperature C OF Resistance Wz 0 32 5 6 20 68 2 4 40 104 1 1 80 176 0 3 3 If the resistance deviates from the standard value greatly replace the sensor INSTALLATION 1 Ap...

Page 200: ...voltage Engine coolant temperature 1621006 Engine coolant temperature sensor A Equipment side connector Engine control module ZPFUO106 OPERATION Refer to P l3A 93 TROUBLESHOOTING HINTS Refer to P l3A...

Page 201: ...T ZPFUO114 SENSOR INSPECTION Refer to 13A 95 INSTALLATION Refer to 13A 95 Measure the impressed voltage l Engine coolant temperature sensor connector Discon nected l Engine control module con nectar...

Page 202: ...sensor Through the resistor in the sensor it is grounded in the engine control module l As the throttle valve shaft rotates from the idle position to wide open position the resistance between the vari...

Page 203: ...disconnected l Ignition switch ON 4 8 5 2 V 02 Repair the harness Al 61 I 2 Check for continuity of the ground circuit l Connector Disconnected 26FU1242 I I I Engine control module harness side conne...

Page 204: ...between terminal 4 sensor ground and terminal 2 sensor output 4 Operate the throttle valve slowly from the idle position to the full open position and check that the resistance changes smoothly in pr...

Page 205: ...rol module is applied to the closed throttle position switch through a resistor When the accelerator pedal is released the closed throttle position switch is turned on to conduct the voltage to ground...

Page 206: ...ed adjust the fixed SAS Refer to P l3A 59 2 Disconnect the throttle position sensor connector 3 Check the continuity across the throttle position sensor connector terminal 4 Sensor ground and 3 Closed...

Page 207: ...ction sequence etc based on the input signal l Power to the camshaft position sensor is supplied from the MFI relay and is grounded to the body The camshaft position sensor generates a pulse signal as...

Page 208: ...gine at an idle speed 2 Connect the probe to the oscilloscope pick up point as shown in the circuit diagram and check the waveform Normal waveform HARNESS INSPECTION l Connector Disconnected 0 Ignitio...

Page 209: ...ignal l Power to the camshaft position sensor is supplied from the MFI relay and is grounded to the body The camshaft position sensor generates a pulse signal as it repeatedly connects and disconnects...

Page 210: ...Z6AF0057 A Harness side connector Z6AF0059 Measure the power supply volt age l Connector Disconnected l Ignition switch ON Battery voltage I relay Check for continuity of the ground circuit l Connect...

Page 211: ...or the engine stalls suddenly during idling shake the crankshaft position sensor harness If this causes the engine to stall poor contact of the sensor connector is suspected Hint 2 If the crankshaft p...

Page 212: ...tes actual engine speed Function Item No Data reading 22 Data display Check condition Coolant temperature Standard value Idle speed 0 gtine Running at At 20 C 4 F 1 300 1 500 rpm l Closed throttle pos...

Page 213: ...496 Measure the power supply volt age 0 Connector Disconnected 0 Ignition switch ON Battery voltage I relay A Harness side connector Z7FUC497 connector Y7FUO496 Check for continuity of the ground circ...

Page 214: ...aracteristic ZSEL1303 I Time _ 27FUO682 Engine control module connector 26AF0060 7FU0653m 7FU1587 OPERATION Refer to P l3A 107 TROUBLESHOOTING HINTS Refer to P l3A 107 INSPECTION Refer to P i3A 108 HA...

Page 215: ...le Inspection of MFI FUEL INJECTION ComDonents 13A 111 A Harness side connector Check for continuity of the ground circuit l Connector Disconnected Z6AF0062 Repair the harness Al Ground A Harness side...

Page 216: ...on switch to the engine control module which detects that the engine is cranking INSPECTION Using Scan Tool Function Item No Data display Check condition I Engine Normal indication 1 Data reading 18 S...

Page 217: ...detects that the engine is cranking In case the selector lever is in a position other than the P N range the battery voltage is not applied to the engine control module l The park neutral position sw...

Page 218: ...nector y ZOlA0206 Harness side connector ZOiA0206 YOl LO427 Measure the input voltage of engine control module l Engine control module connec _ P I A tor Disconnected l PNP switch connector Con nected...

Page 219: ...SWITCH PNP SWITCH CAIT From 1993 models lqnition switch ST A Equipment side connector I OPERATION Refer to P l3A 113 TROUBLESHOOTING HINTS Refer to P l3A 113 PNP switch 8 r k Starter S MFI terminal re...

Page 220: ...or Dis w P l connected I 0 Ignition switch START Battery voltage Check the power supply I circuit Check for continuity between the PNP switch and engine control module f Y I l Engine control module co...

Page 221: ...peed into a pulse signal and inputs it to the engine control module which then provides the idle speed control etc based on this signal l The vehicle speed sensor generates the vehicle speed signal by...

Page 222: ...PORT On Vehicle Inspection of MFI FUEL INJECTION Components A Harness side l Connector Disconnected l Ignition switch ON 0 Connector Disconnected SENSOR INSPECTION Refer to GROUP 54 Meters and Gauges...

Page 223: ...O653 7FUl592 OPERATION l The vehicle speed sensor mounted directly to the speedometer driven gear of the transmission converts the vehicle speed to the pulse signal to be input to the engine control m...

Page 224: ...y voltage L L I tion switch Check the vehicle speed sensor output circuit for continuity l Engine control module con f 1 A nectar Disconnected l Ignition switch ON C l Move the vehicle Continuity C o...

Page 225: ...of power steering load into low high voltage and inputs it to the engine control module which then controls the idle air control motor based on this signal l The battery voltage in the engine control...

Page 226: ...ght forward Turned Oil pump delivery pressure ref value 700 l 200 kPa loo 171 psi 1 500 2 000 kPa 213 284 psi HARNESS INSPECTION A Harness side connector Measure the power supply volt age 0 Connector...

Page 227: ...input the engine control module drives the idle air control motor and turns ON the power transistor As a result the air conditioning power relay coil is energized to turn on the relay switch which act...

Page 228: ...fter OFF ing relay OFF compressor I warm up clutch non activa state tion ON ON compressor clutch activation HARNESS INSPECTION II 1 120 Engine control module Engine control module harness side connect...

Page 229: ...the magnitude of cylinder block vibration due to knocking and inputs it to the engine control module Based on this signal the engine control module provides retard control of the ignition timing TROU...

Page 230: ...13A 126 MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Components HARNESS INSPECTION harness side short circuit to nectar Disconnected 0 Connector Disconnected I j I I I I d TSB Revision...

Page 231: ...odule Based on this signal the engine control module controls the idle air control motor l When the switch of equipment with a large electrical load is turned ON the battery voltage is applied to the...

Page 232: ...put voltage of en Battery voltage Check circuit related to tail light relay Measure the input voltage of en gine control module l Engine control module con nector Disconnected l Defogger switch ON Def...

Page 233: ...s 13A 129 FAN MOTOR RELAY RADIATOR AIR CONDITIONING CONDENSER From 1994 models Ignitionswitch IG Air conditioner compressor lock controller Engine control module connector 1 TSB Revision 27FltO653 To...

Page 234: ...the current flows to the condenser fan motor relay Lo The condenser fan motor relay Lo will operate to send driving power supply for low speed rotation from the battery to the condenser fan motor If t...

Page 235: ...de muffler control l The output terminal of the muffler mode changeover switch has battery voltage applied to it from the engine control module through the resistor inside the module Place the muffler...

Page 236: ...EL INJECTION Components HARNESS INSPECTION A H connector 27FU1054 Measure the power supply volt age l Connector Disconnected l Ignition switch ON Battery voltage Repair the harness A3 108 A Harness si...

Page 237: ...to the engine control module which provides valve opening and closing control based on this signal l The induction control valve position sensor is supplied with 5V power engine control module and is...

Page 238: ...he power supply volt age of the air intake control valve 4 8 5 2 V f Repair the harness Al 61 A Harness side connector Check for continuity of the ground circuit l Connector Disconnected 27FUO824 Repa...

Page 239: ...n indicator lamp is turned on to notify the driver l Five volt power supply in the engine control module is applied to the EGR temperature sensor through the resistance in the module This power supply...

Page 240: ...tes or more Disconnect vacuum hose green stripe from EGR solenoid and install blind caps to removed vacuum hose end and solenoid nipple Engine state 700 rpm Idle 3 500 rpm Standard value 100 C 212 F o...

Page 241: ...a voltage and inputs it to the engine control module l The heated oxygen sensor outputs about 1 V when the air fuel ratio is richer than the theoretical ratio and outputs about 0 V when the ratio is l...

Page 242: ...ed to air fuel ratio control system are suspected Examples L 1 Faulty injector 2 Air leaking into the intake manifold through gasket gap etc 3 Faulty volume air flow sensor intake air temperature sens...

Page 243: ...Repair the harness A3 MFI relay Er1gine control Check for an open circuit or a module harness short circuit to ground between the engine control module and the heated oxygen sensor l Heated oxygen se...

Page 244: ...4 of the heated oxygen sensor connector to battery and terminals respectively Caution Ensure that the jumper wires are connected correctly as wrong connections result in a broken heated oxy gen senso...

Page 245: ...y Z7FU1332 TFU1602 OPERATION Refer to P l3A 137 TROUBLESHOOTING Refer to P l3A 138 INSPECTION Using Scan Tool Function Item No Data display Check condition Engine condition Standard value Data reading...

Page 246: ...switch ON Battery voltage I hFi relay Check for an open circuit or a short circuit to ground between the engine control module and the heated oxygen sensor l Heated oxygen sensor con nector Disconnect...

Page 247: ...nsor connector to battery and terminals respec tively Caution Ensure that the jumper wires are connected correctty as wrong connections result in a broken heated oxy gen sensor 6 Connect a digital vol...

Page 248: ...module l The injector has a fixed nozzle opening area and the fuel pressure against manifold inside pressure is regulated to a fixed level Therefore the volume of fuel injected by the injector is det...

Page 249: ...ta 41 Drive time reading Engine Cranking 0 C 32 F 2 15 3 18 7 ms Up to 1993 models 13 8 16 8 ms From 1994 models 20 C 68 F 41 4 50 6 ms Up to 1993 models 40 48 8 ms From 1994 models 80 C 176 F 9 9 12...

Page 250: ...3A0209 HARNESS INSPECTION J 1 Harness side connector 27FUO669 Harness side connector 27FUO970 Harness side connector 1 I 8 33 I i i i 27FUO805 Measure the power supply volt age of the front bank injec...

Page 251: ...con nector Disconnected 1 i41516 ACTUATOR INSPECTION Measurement of Resistance between Front Bank Terminals 1 Remove the injector connector 2 Measure the resistance between terminals Standard value 13...

Page 252: ...7FUO832 MFI relay A Equipment side connector 6 Inject01 No 3 r 1 Q5 rI 4 P Injector No 2 OSCilla 1 3 b 7 4 Inject0 _ bisal3 14 K 5 5 Inject0 No 6 I5 K 6 E Rear bank connector I I r 1 3 A Engine contro...

Page 253: ...upply voltage is 11 V and the cranking speed is less than 250 rpm 2 When coolant temperature iis lower than 0 C 32 F injection is made by 6 cylinders simultaneously 3 When the vehicle is new within in...

Page 254: ...t bank injector l Resistor connector Con necteu l Injector connector Discon netted l Ignition switch ON Repair the harness B C Dl MFI relay Battery voltage Check pow er supply Check resis tor Measure...

Page 255: ...nected ACTUATOR INSPECTION INJECTORS Measurement of Resistance between Front Bank Terminals 1 Disconnect the injector connector 2 Measure the resistance between terminals Standard value 2 3 0 at 20 C...

Page 256: ...SISTOR Measurement of Resistance between Terminals 1 Disconnect the resistor connector 2 Measure the resistance between terminals I Measuring terminals I Resistance 1 4 2 4 VI k E65c 88 F 1 I 8 4 I 3...

Page 257: ...MFI relay As the engine control module turns on power transistors in the module one after another the stepper motor coil is energized and the motor rotates in normal or reverse direction TROUBLESHOOTI...

Page 258: ...switch ON compressor clutch to be ON if airconditioning switch is ON l Engine Idling Load state Standard value Air conditioning switch 2 25 step OFF Air conditioning switch Increase by ON 1 O 70 step...

Page 259: ...t or a short circuit to around between the engine contr l module andthe idle air control motor l Enoine control module con nectar Disconnected l Idle air control motor connec Repair the tor Disconnect...

Page 260: ...t the idle air control motor side Standard value 28 33 Q at 20 C 68 F 3 Measure the resistance between terminal 5 green clip of the special tool and either terminal 6 yellow clip or terminal 4 black c...

Page 261: ...n of the stepper motor 1 Connect the negative terminal of the power supply to the red and black clip 2 Connect the negative terminal of the power supply to the blue and black clip 3 Connect the negati...

Page 262: ...ignition power transistor unit A is turned off the primary current is shut off and a high voltage is induced in the secondary coil A causing the ignition plugs of No 1 and No 4 cylinders to spark Whe...

Page 263: ...erminal condition Standard value ignition timing adjust ON ment terminal is grounded Ignition timing adjust OFF ment terminal is discon nected from ground Drive I Check condition I Normal condition I...

Page 264: ...s side co Measure the power supply volt age of the ignition coil l Connector Disconnected l Ignition switch ON Battery voltage 0 OK 0 2 Repair the harness A3 Igni tion switch ZOl Lo4ll 0 Ignition powe...

Page 265: ...it l Connector Disconnected cl 6 1 bound Measure the voltage of the control signal circuit of the ignition power transistor l Connector Disconnected e Ignition switch START 0 5 4 0 v Repair the harnes...

Page 266: ...h controls introduction of purge air from the canister into the intake air plenum o The battery power is supplied to the evaporative emission purge solenoid through the MFI relay When the engine contr...

Page 267: ...ss MFI relay A l Check for an open circuit or a short circuit to ground between the evaporative emission purge solenoid and the engine control module l Engine control module con nectar Disconnected l...

Page 268: ...ting negative pressure to the throttle body A port l Power supply from the battery is sent through the MFI relay to the EGR solenoid When the engine control module turns off the power transistor insid...

Page 269: ...r supply volt aae l Connector Disconnected 0 Ignition switch ON Battery voltage 1 relay Check for an open circuit or a short circuit to ground between the EGR solenoa and the engine control module 0 E...

Page 270: ...3 7FU1609 OPERATION l The fuel pressure solenoid is an ON OFF type solenoid valve that switches the pressure introduced to the fuel pressure regulator between either intake manifold pressure or barome...

Page 271: ...SS INSPECTION A Harness side connector Measure the power supply volt age l Connector Disconnected att zt h ON Repair the harness Al MFI relay ZOlA0524 Engine control module harness side CO Check for a...

Page 272: ...ack from the solenoid valve 2 Disconnect the harness connector 3 Apply a negative pressure to the nipple to which the black vacuum hose has been connected and check air tightness with and without the...

Page 273: ...attery power is supplied to this valve via the MFI relay When the engine control module turns ON the internal power transistor the coil is energized to release part of the boost pressure applied to th...

Page 274: ...nnector l Measure the power supply volt age l Connector Disconnected 0 Ignition switch ON Battery voltage QCCQ J Repair the harness Al MFI r relay z7Fw525 connector Check for an open circuit or a shor...

Page 275: ...f MFI FlJEL INJECTION Components 13 9171 BOOST METER Turbo r A l l 4 I449 I 7 E 22 lb I I teiter fy Boost ry Ignition switch IG I A Equipment side connector Boost meter Engine control module connector...

Page 276: ...ttery voltage 1 Z7FUO986 Repair the harness A2 Igni tion coil IG Engine controt moduts Check for an open circuit or a short circuit to ground between the engine control module and the boost meter l Bo...

Page 277: ...the normal or reverse direction l The DC motor is driven in the normal or reverse direction by changing the direction of power flow by the motor driving IC in the active exhaust control unit l The ac...

Page 278: ...is driven clockwise or counterclockwise by the signal from the engine control module the variable induction valve opens or closes l The DC motor is driven clockwise or counterclockwise as the directi...

Page 279: ...INSPECTION Engine control module connector f2 27FUO841 Check for an open circuit or a short circuit to ground between the engine control module and the variable induction control motor connector l Va...

Page 280: ...ot the motor relay is activated Based on this signal the engine control module controls the idle air control motor to secure effective anti lock braking l When the motor relay is activated the ABS con...

Page 281: ...ed in the engine control module This will change the terminal voltage of the transaxle control module from HIGH to LOW If the transistor fitted inside the engine control module changes from ON to OFF...

Page 282: ...harness side connector Engine control modu e hamess Check for an open circuit or a short circuit to ground between the transaxle control module and the engine control module l Transaxle control modul...

Page 283: ...uel pump harness connector 5 Apply the specified sealant to the rear floor pan Specified sealant 3M ATD Part No 8509 or equivalent 6 Install the fuel gauge cover FUEL PUMP OPERATION CHECK 1 Set the ig...

Page 284: ...vent fuel leaks 4 Attach the special tool set in step 3 to the fuel rail between high pressure hoses 5 Connect a jumper wire to the terminal for activation of the fuel pump and to the positive termina...

Page 285: ...to gently press the fuel return hose while repeatedly racing the engine and check to be sure that there is fuel pressure in the return hose also NOTE There will be no fuel pressure in the return hose...

Page 286: ...rop of the The check valve within the fuel pump Replace the fuel pump fuel pressure immediately after the is not closed engine is stopped 14 Reduce the internal pressure of the fuel pipes and hoses 15...

Page 287: ...tor terminal and ground could cause damage to the vehicle wiring sensors or ECM or all of them Use care to prevent it 3 If the voltmeter shows any deviation from the standard value check the correspo...

Page 288: ...13A 184 MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Comtaonents Camshaft position sen 1TSB Revision...

Page 289: ...r conditioning switch OFF ON Air more for a mo compressor in driven state ment O 3 V as A C clutch cycles 6 Fan motor relay Lo Radiator fan not operating B 1994and Coolant temperature below 90 C 194 F...

Page 290: ...ium gasoline is O 3 V used 11 Turbo meter 21 Fuel pump relay 2 Ignition switch ON 4 13 v Turbo Engine Depress the accelerator pedal Falls temporari abruptly while the engine is idling ly from B Engine...

Page 291: ...ontrol valve Engine Slowly decelerated from 5 000 rpm for a moment Closed to idling speed Anti lock braking signal Engine Idle B Turbo l When vehicle is put in motion for the B 3 O 3 V first time afte...

Page 292: ...e sensor Evaporative emission purge solenoid Fuel pressure solenoid Turbo Heated oxygen sensor Idle air control motor stepper motor B Variable induction control motor DC motor with built in in J X duc...

Page 293: ...e air temperature sensor and barometric pressure sensoc bank heated oxygen wxor rear 5cl nia T u r and Federal Turbo from 1996 l d ge I 1 sensor fro1 P Electrical Speedometer Type 1 i 2 y Heated oxyge...

Page 294: ...13A 190 MULTIPORT On Vehicle Inspection of MFI FUEL INJECTION Components Variable air intake control s DC motor with built in air intak Injector I I 27FUO803 rtrad dt ode R16FOSQO 1 TSB Revision...

Page 295: ...of MFI FUEL INJECTION Components 13A 191 ZlBFO292 California up to 1995 Imodels _ Federal Turbo up to 1995 models I v _E_G_ veraturel Iii i Z7FUlOlOI piagnostic output terminal and agnostic test mode...

Page 296: ...IPORT On Vehicle Inspection of MFI FUEL INJECTION Components Camshaft position sensor From 1996 models Turbo 1 Non T u r b o Manifolddifferential pressure sensor Manifolddifferential pressure sensor T...

Page 297: ...A 64 POWER SUPPLY MFI RELAY AND IGNITION SWITCH IG Up to 1995 models En ine control module I 1 16FO292 7FUO927 OPERATION MFI relay 4 8 6 Ignition switch IG A r 4 A Equipment side connector A Harness s...

Page 298: ...elay l Ignition switch OFF l MFI relay connector Discon 0 nected I Battery voltage Repair the harness Battery 21 FUO808 A4 A8 Engine control module harness Check for an open circuit or a side connecto...

Page 299: ...e r 1 Measure power voltage to the ac tuator connector I 26AFOO51 l MFI relay connector Con nected l Engine control module con nector Connected Engine cranking 8 V or higher Engine racing Battery volt...

Page 300: ...ELAY AND IGNITION SWITCH IG From 1996 models Battery fl I lcmitionjvitch WI Y Engi mod A Equipment side connector 1 2 ED 3 4 r MFI relay 1 Engine control module 1 7FUl833 32 Engine control module conn...

Page 301: ...ctor side connector Engine control module harness side connector 17FU1824 Check for an open circuit or a short circuit to ground between the engine control module and the MFI relay l Engine control mo...

Page 302: ...I I Continuity approx 70 Q I 3 Use the jumper leads to connect relay terminal 4 to the battery terminal and terminal 2 to the battery termi nal 4 Check the continuity between relay terminals 1 3 while...

Page 303: ...N Components 13A 199 ENGINE CONTROL MODULE POWER GROUND Engine control module 4 ZOlAOlQl Engine control module connector zpFuo393 7FU1617 OPERATION Refer to 13A 71 TROUBLESHOOTING HINTS LJ Refer to 13...

Page 304: ...pump connector 03FOOM Ignition switch IG 7 r MFI relay Engine control module 8 I n C Fuel pump check terminal I OPERATION Refer to 13A 76 INSPECTION Refer to 13A 73 HARNESS INSPECTION Refer to 13A 77...

Page 305: ...heck terminal Ignition switch IG A Equipment side connector a b cm L U 63 tol Fuel pump connector Fuel pump 7 B Equipment B Harness side connector Engine control C Fuel pump check terminal f module r...

Page 306: ...ge to the checking terminal and oper ate the pump Check the ground circuit of the fuel pump l Fuel pump connector Dis connected I bround Check for continuity between the fuel pump and the checking ter...

Page 307: ...y voltage switch A3 A4 or check the ignition switch short circuit to ground bekeen the MFI relay and the engine con l Engine control module con nectar Disconnected Repair the harness W 8 the MFI relay...

Page 308: ...FUEL PUMP Turbo Up to 1995 models Equipment side connector A Harness side connector Ignition switch IG E Equipment sidl B Harness side 1 Equipment side connector J m t e r m i n a l C Fuel pump check...

Page 309: ...the ground circuit of the 4 t Repair the harness B2 Ground Check for continuity between the fuel pump and the checking termi nal l Fuel pump connector Dis connected Repair the harness Bl Cl Harness si...

Page 310: ...Check for continuity between the fuel pump relay II and the resistor for fuel pump l Fuel pump relay II connector Disconnected l Resistor for fuel pump con nector Disconnected Repair the harness D4 E...

Page 311: ...hicle Inspection of MFI FUEL INJECTION Comraonents 13A 207 short circuit to Fuel pump relay II connector Disconnected D Harness side l Fuel pump connector Dis MFI RELAY INSPECTION Refer to P l3A 70 i...

Page 312: ...A Ignition switch IG Fuel pump connector 03FOOO4 Fuel pump relay II D Equipment side connector 1 4 2 Fuel pump circuit resistor 8 E Equipment side connector Engine control module connector 2 rFuel pum...

Page 313: ...ON l Fuel pump connector Dis connector Harness side Check for continuity between the co r checking terminal and the fuel pump relay II and between the re sistor for fuel pump l Fuel pump relay II conn...

Page 314: ...the power supply volt age of the MFI relay l MFI relay connector Discon netted Ignition switch OFF 0 V Ignition switch ON Battery voltage Harness side IDI connector 7FUl822 1A Harness side connector E...

Page 315: ...pump relay II and the fuel n A pump l Fuel pump relay II connector Disconnected j LTOA 0 Fuel pump connector Dis connected Repair the harness Bl D2 MULTIPORT FUEL INJECTION MFI RELAY AND FUEL PUMP REL...

Page 316: ...ume air flow sensor A Harness side connector 7 6 5 4 3 2 1 SEL1803 I relay Engine control module J 7FUO654 Engine control module connector ZPFUO393 1 Function 1 Item No Data display 1 Check condition...

Page 317: ...l Operation range idling to maximum output 15 35 Non Turbo 1 lo 30 Turbo Volume Air Flow Sensor Reset Signal tm N o lnct n Reset signal condition Data display Check conditions l Engine warm up 1 700 r...

Page 318: ...omponents HARNESS INSPECTION l Connector Disconnected l Ignition switch ON l Connector Disconnected volume air flow sensor and the engine control unit 0 Volume air flow sensor con nector Disconnected...

Page 319: ...sor intake air temperature sensor OPERATION Refer to P l3A 88 TROUBLESHOOTING HINTS Refer to P l3A 88 INSPECTION Refer to P l3A 89 Resistance I Temperature 2162460 A Equipment side connector Output vo...

Page 320: ...JECTION Components HARNESS INSPECTION l Connector Disconnected 2 7FUO657 A Harness side 1 l Repair the harness A592 Measure the power supply volt SENSOR INSPECTION Refer to P l3A 89 age 0 Connector Di...

Page 321: ...t voltage V Barometricpressure mmHg in Hg KISS OPERATION Refer to P l3A 91 TROUBLESHOOTING HINTS Refer to P l3A 92 INSPECTION Refer to P l3A 92 A EQuiDment side coitriector Barometric pressure sensor...

Page 322: ...Disconnected Repair the harness AS 92 Measure the power supply volt age of the barometric pressure sensor l Y l Connector Disconnected l Ignition switch ON 4 8 5 2 v Repair the harness Al 81 Check fo...

Page 323: ...L Resistance t I ___ Coolant temperature lOZ4l8 Coolant temperature 1621008 I Engine coolant temperature sensor Engine control module connector A Equipment connector Engine control module 9FUO393 OPER...

Page 324: ...ture sensor connector Discon netted Repair the harness r A2 92 Z9FUO112 i I Measure the impressed voltage A Harness side l Engine coolant temperature connector a q sensor connector Discon nected a Eng...

Page 325: ...Throttle shaft turning angle 2162461 OPERATION Refer to P l3A 98 TROUBLESHOOTING HINTS Refer to P l3A 98 INSPECTION Refer to P l3A 99 A Equipment side connector Throttle position sensor A Harness sid...

Page 326: ...of MFI Components HARNESS INSPECTION A Harness side connector l Connector Disconnected l Throttle position sensor con nector Disconnected Engine control module con nector Disconnected nals like ECM D...

Page 327: ...A Harness side connector Terminal voltage V OFF m e Ii I 1 Throttle shaft turning anglezo t002 OPERATION Refer to P l3A 101 TROUBLESHOOTING HINTS Refer to P l3A 101 INSPECTION Refer to P l3A 101 A Eq...

Page 328: ...7FUO675 A 2 m Z k I gJ 0 I26FU1242 L Measure the power supply volt age of the closed throttle position switch l Connector Disconnected 0 Ignition switch ON 4 V or more Repair thl harness A3 87 Check f...

Page 329: ...on sensor 7FU130t IV1 Output characteristic No 1 5 v No 4 Z7FUO677 Engine control module connector A Equipment side connector OPERATION Refer to P l3A 103 TROUBLESHOOTING HINTS Refer to P l3A 103 INSP...

Page 330: ...mDonents HARNESS INSPECTION Measure the power supply volt age l Connector Disconnected 0 Ignition switch ON Battery voltage Repair the harness A3 MFI 27FU1330 relay A Harness side l Connector Disconne...

Page 331: ...Data display Check condition Cranking l Engine cranking speed l Tachometer connected check on and off of primary current of ignition coil by tachometer 7FU1626 Check content Normal state Compare cran...

Page 332: ...1 275 1 475 rpm switch ON 1 300 l 500 rpm 2 At 0 C 32 F 1 225 1 425 rpm 1 300 l 500 rpm 2 At 2O C 68 F l lOO 1 300 rpm l 1 300 l 500 rpm 2 At 4O C 104 F 950 1 150 rpm 1 050 l 250 rpm 2 At 8O C 176 F...

Page 333: ...ition switch ST I 7FUl629 Engine control Measure the input voltage to the module harness engine control module side connector l Engine control module con nectar Disconnected 0 Ignition switch START I...

Page 334: ...ontrol module 7FU1320 Engine control module connector zpFuo393 7FU1630 OPERATION Refer to P i3A 113 TROUBLESHOOTING HINTS Refer to P l3A 113 INSPECTION Refer to P l3A 114 HARNESS INSPECTlON A Harness...

Page 335: ...connector Measure the impressed voltage to the PNP switch l Engine control module con nector Connected l PNP switch connector Dis connected 0 Ignition switch ON Bakery voltage 0 OK 7A STOP Replace th...

Page 336: ...CTION _ On Vehicle Inspection of MFI Components OPERATION Refer to P l3A 117 TROUBLESHOOTING HINTS Refer to P l3A 117 HARNESS INSPECTION onnector Disconnected SENSOR INSPECTION Refer to GROUP 54 Meter...

Page 337: ...ometer Type Terminal voltage V Frequency Hz 2162478 Vehicle speed km h mph 2162451 OPERATION Refer to P l3A 119 TROUBLESHOOTING HINTS Refer to P l3A 117 A Equipment side connector Ignition switch WI E...

Page 338: ...itch Check the vehicle speed sensor output circuit for continuity l Engine control module con nector Disconnected l Ignition switch ON l Move the vehicle Engine control Continuity module harness side...

Page 339: ...A Harness side connector L p 3 7 Power steering pressure switch 1 A Harness side connector En Z7FUO536 7FU1633 OPERATION Refer to P l3A 121 INSPECTION Refer to P l3A 122 HARNESS INSPECTION Measure th...

Page 340: ...ine control module connector I d 27FUO966 mFuo393 OPERATION Refer to P l3A 123 TROUBLESHOOTING HINTS Refer to P l3A 123 INSPECTION Refer to P l3A 123 HARNESS INSPECTION 7FU1634 I 1 Engine control modu...

Page 341: ...5 Engine control module connector 29Fuo393 7FU1635 OPERATION Refer to P l3A 125 TROUBLESHOOTING HINTS Refer to P l3A 125 HARNESS INSPECTION Engine control module harness side connector r connector 78...

Page 342: ...k for continuity of the ground 2A STOP I bound ELECTRICAL LOAD SWITCH Engine control module connector Defog ger t relay I NOTE up to 2 From Engine control module 1995 models 1996 models 27FUO688 7FU16...

Page 343: ...ure the input voltage of en gine control module l Engine control module con nectar Disconnected 0 Defogger switch ON Defogger relay ON Engine control module harness side connector 27FUO689 Battery vol...

Page 344: ...AIR CONDITIONING CONDENSER z Battery z E I Ignition switch IG ECM Radiato fan mote relay 1 r1I Lo r 3r I 7 21 b i f 0 I 7c 4 1 Ari 4 w To air conditioning compressor u 0 Air conditioning compressor l...

Page 345: ...I l Ignition switch ON Battery voltage Check the fan motor ECM harness side connector relay circuit Z6FU2008 FAN MOTOR RELAY INSPECTION Refer to Radiator Check in GROUP 14 and Power Relay Check in GRO...

Page 346: ...34 61 Checkforcontinuity of the ground circuit l Connector Disconnected Repair the harness A2 Ground NOTE 1 Up to 1995 models From 1996 models INDUCTION CONTROL VALVE POSITION SENSOR Non Turbo Variabl...

Page 347: ...the power supply volt age of the air intake control valve A Harness side connector 7 El l L H z 0 n c 27FUO824 A Harness side fc Z7FUO825 NOTE 1 Up to 1995 models From 1996 models Check for continuit...

Page 348: ...fold differential pressure switch converts the intake manifold plenum pressure to the voltage and inputs to the engine control module Engine control module confirms the operation of EGR system from th...

Page 349: ...92 9FUO414 LJ Engine control module harness side connector 74 t 9FUO415 Check for open circuit or short circuit to ground between the en gine control module and the man ifold differential pressure se...

Page 350: ...nia Up to 1995 models Federal Turbo Up to 1995 models A Equipment side EGR temperature sensor connector A Harness side t output voltage 1 I Temperature Z 6Z1008 OPERATION Refer to P l3A 135 INSPECTION...

Page 351: ...harness A Al 92 SENSOR INSPECTION Refer to GROUP 17 Exhaust Gas Recirculation EGR System HEATED OXYGEN SENSOR California Non Turbo Up to 1995 models ii 49 ii Riaht bank II L I Right bank heated oxygen...

Page 352: ...condition of control by the engine control mod ule Engine state Standard value When sudden deceleration from 4 000 rpm When engine is suddenly raced 700 rpm Idling 2 000 rpm 200 mV or lower 600 1 000...

Page 353: ...nector 74 i I 77 27FUl440 Check for an open circuit or a short circuit to ground between the engine control module and the heated oxygen sensor 0 Heated oxygen sensor con nectar Disconnected l Engine...

Page 354: ...6 ZECIOO L A Equipment connector i Al Heated oxygen Heated oxygen B Equipment side connector T I MFI re ay Engine con Engine control module connector OPERATION Refer to P l3A 137 TROUBLESHOOTING Refer...

Page 355: ...Z7FU1333 MFI relay Check for an open circuit or a short circuit to ground between the enginecontrol module and the heated oxygen sensor l Heated oxygen sensor con nector Disconnected l Engine control...

Page 356: ...P l3A 138 INSPECTION Using Scan Tool Heated Oxygen Sensor front Function Data reading b item No Data display Check condition 11 39 Sensor Engine Warm up Make the mixture detection lean by engine speed...

Page 357: ...re the power supply volt age of the heated oxygen sensor a Connector Disconnected f Y __ l Ignition switch ON OK I 2 I Battery voltage Repair the harness Al Bl Cl Dl MFI relay short circuit to ground...

Page 358: ...s the oxygen concentration in exhaust gas converts it into a voltage and inputs it to the engine control module l The heated oxygen sensor outputs about 1 V when the air fuel ratio is richer than the...

Page 359: ...e Check condition Engine Warm up Make the mixture lean by engine speed reduction and rich by racing t Engine Warm up Using the heated oxygen sensor signal check the air fuel mixture ra tio and also ch...

Page 360: ...sor l Heated oxygen sensor con nectar Disconnected l Engine control module con nectar Disconnected i l D l MFI relay A B C D Harness sid connector Engine control module harness side connector L J 7FUl...

Page 361: ...ger 3 Needle valve Y Fuel Filter Injection 7FUO832 MFI relay 1 A 2 ii h Injector No 2 i _ _ _ _ _ _ 1 B 1 2 3 1 Injector 1 No 4 1 2 1 lnjectoi NO 6 1 2 _ _ 3 oscillo 15 I 12 4 D Connector for rear ban...

Page 362: ...To increase l The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm 2 When coolant temperature is lower than 0 C 32 F injection is made by 6 cyl...

Page 363: ...ut off after engine warm up check the idling condi No 5 injector shut off tion 1 06 No 6 injector shut off I Normal state Idle state to change fur ther becoming less stable or stalling z A injector dr...

Page 364: ...Fuel Solenoid coil Plunger q Needle valv Connector Filter Injection 7FUO832 OPERATION Refer to P l3A 144 TROUBLESHOOTING HINTS Refer to P l3A 145 lnjectc No 1 MFI relav E 4 Resistor _ _ A Equipment s...

Page 365: ...ncrease l The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm 2 When coolant temperature is lower than 0 C 32 F injection is made by 6 cylinde...

Page 366: ...le or stalling sequence during idling No 4 injector shut off after engine warm up check the idling condi No 5 iniector shut off tion I No 6 injector shut off J 1 A A injector drive time Normal wavefor...

Page 367: ...Y r MFI relay I 2 5 A Y G i 1 3 T Oscillo Oscillo I I r 1 A Equipment side connector IAC motor Oscillo Oscillo n I A 4 h17h5 A 18 __ Engine control module V v 0 V Z7FUO518 Engine control module connec...

Page 368: ...uipment side connector B Harness side connector r 1 Ii B l B 2 I _ i Tachometer __ Engine control module G r 5 v Batterv Engine speed check control terminal 13 Ignition coil g 5 7 iransistor bll ignit...

Page 369: ...terminal is grounded Ignition timing adjust OFF ment terminal is discon nected from ground Standard Ignition Timing id Function Item No Drive Check condition Normal condition Actuator test 17 Set to i...

Page 370: ...gnition coil l Connector Disconnected 0 Ignition switch ON Battery voltage Repair the harness B6 Igni tion switch i Check for an open circuit or a short circuit to ground between the engine control un...

Page 371: ...he ground circuit 0 Connector Disconnected 27FUO700 Repair the harness B4 Ground Measure the voltage of the control signal circuit of the ignition power transistor l Connector Disconnected 0 Ignition...

Page 372: ...NOID MFI relay EVAP purge solenoid Engine control module I j d side 7FU1851 Engine control module connector I 9FUO393 d 7FUl850 OPERATION Refer to P l3A 162 INSPECTION Refer to P l3A 162 HARNESS INSPE...

Page 373: ...GR SOLENOID EGR solenoid J 1 Cl O MFI relay T EGR solenoid Engine control module Engine control module connector 7FU1649 OPERATION Refer to P l3A 164 TROUBLESHOOTING HINT Refer to P l3A 164 INSPECTION...

Page 374: ...s 2 From 1996 models Engine control module connector 29Fuo393 7FU1650 OPERATION Refer to P l3A 166 INSPECTION Refer to P l3A 167 HARNESS INSPECTION I 1 A Harness side connector Measure the power suppl...

Page 375: ...ressure solenoid and the engine control module n A l Engine control module con OK roA nectar Disconnected I a Fuel pressure solenoid con nector Disconnected Repair the harness A2 7 403 YOlA0525 NOTE I...

Page 376: ...CTUATOR INSPECTION Refer to GROUP 15 T Measure the power supply volt age Connector Disconnected l Ignition switch ON Battery voltage I relay Check for an open circuit or a short circuit to ground betw...

Page 377: ...gnition switch IG A Equipment side connector Engine control module NOTE Up to 1995 models 2 From 1996 models 7FUO985 Engine control module connector 29Fuo393 7FU1662 A Harness side connector Z7FUO986...

Page 378: ...f MFI FUEL INJECTION Components Z7FUO987 NOTE I Up to 1995 models 2 From 1996 models ACTUATOR INSPECTION Refer to GROUP 54 l Engine control module con nector Disconnected Repair the harness A3 41 39 2...

Page 379: ...35 7 2 r Measure the input voltage of en gine control module 0 Engine control module con nector Disconnected 0 Ignition switch ON Battery voltage A Repair the Engine control harness module harness si...

Page 380: ...control motor ZlFUO646 ZPFUO393 7FU1654 OPERATION Refer to P l3A 174 INSPECTION Refer to P l3A 174 HARNESS INSPECTION Enaine control module hasess side connector ACTUATOR INSPECTION Refer to GROUP 15...

Page 381: ...ECU Engine control module d r 5 v 28 ABS HU 44 J Z6FU1542 OPERATION Refer to P l3A 176 HARNESS INSPECTION Engine control module 26FU1543 Check for an open circuit or a short circuit to ground between...

Page 382: ...TAL CONTROL SIGNAL A T 16FO292 Transaxle control module 7r NOTE l Up to 1995 models 2 From 1996 models I Engine control module f I 27 FUO903 7 46 A Transaxle control module connector 5v P Z7FUO843 6 9...

Page 383: ...control module connector Disconnected l Engine control module con nector Disconnected Repair the harness A7 46 Check for an open circuit or a short circuit to ground between the transaxle control modu...

Page 384: ...terminal ground terminal 3 Withdraw the ECM for easier access to the connector terminals 4 The inspection need not be performed in the order of the chart Caution Short circuiting the positive probe be...

Page 385: ...altitude is 0 m 0 ft 3 7 4 3 V switch ON When altitude is 3 2 3 8 V 1 200 m 3 937 ft Ignition When water temperature 3 2 3 8 V switch ON is 0 C 32 F When water temperature 2 3 2 9 V is 20 C 68 F When...

Page 386: ...ditioning switch set B to ON Non Turbo l From 1996 Indoor set temperature models brought closer to atmo spheric temperature 22 Air conditioning relay 21 Fan motor relay Lo l Engine Idle B or 6 V or 0...

Page 387: ...Warm B O 3V Al Check immediately after hot restart Changed 17 Stepper motor coil repeated A2 5 Stepper motor coil Bl 18 Stepper motor coil B2 10 Ignition power transistor unit A Engine speed 3 000 rpm...

Page 388: ...ound 36 Check engine malfunc Ignition switch OFF ON o 3v tion indicator lamp 9 13 v Several se conds later 6 EGR solenoid Ignition switch ON B up to 1995 California Non Engine Idle Suddenly depress th...

Page 389: ...o Induction control valve Engine Slowly decelerated from 5 000 rpm for a moment Closed to idling speed Anti lock braking signal Engine idle B Turbo 0 When vehicle is put in motion for the B O 3 V firs...

Page 390: ...ervice Refer to GROUP 15 Intake Manifold Plenum ZO3FOO17 00002423 O ring 03N0012 4 O ring 03FOO18 Engine oil Removal steps A C 1 High pressure fuel hose connection 2 Fuel return hose connection 3 Vacu...

Page 391: ...reinsert it into the fuel rail and check again BA FUEL PRESSURE REGULATOR INSTALLATION 1 Apply a small amount of new engine oil to a new O ring and insert it to the fuel rail carefully Caution Do not...

Page 392: ...cuum nose connectron 4 TPS connector connection 5 ISC motor connector connection 7 Vacuum pipe assembly 8 Throttle body A4 9 Gasket 6 Water hose connection NOTE The layout of vacuum hoses No 3 of the...

Page 393: ...e Manifold Removal and Installation Plenum Refer to GROUP 15 Intake Manifold 20 25 Nm 14 18 ft lbs 203FOO21 A A 1 Knock sensor REMOVAL SERVICE POINT qA KNOCK SENSOR REMOVAL Remove the knock sensor wit...

Page 394: ...NOTES...

Page 395: ...FUEL FILTER 10 SPECIFICATIONS 2 FUEL LINE AND VAPOR LINE 8 General Specifications 2 Sealant 2 FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY AND FUEL TANK PRESSURE TROUBLESHOOTING 2 CONTROL VALVE 6 Fuel Tank...

Page 396: ...acity dm3 gal 75 19 8 1Return system Equipped I I I I 1 Filter 1 High pressure type SEALANT Items Specified sealant Fuel tank hole cover 3M ATD Part No 8509 or equivalent TROUBLESHOOTING FUEL TANK AND...

Page 397: ...Nm 8 ft lbs 25 Ribs v 203F0007 26 Nm 19 ft lbs Removal steps Fq 1 Fuel gauge cover 2 Fuel pump and fuel gauge assembly connector 3 Fuel tank cap 4 Drain plug 5 Splash shield 6 Fuel tank filler tube p...

Page 398: ...the pipe has a stepped part connect the vapor hose to the pipe securely up to the stepped part as shown in the illustration 2 If the pipe does not have a stepped part connect the vapor hose to the pip...

Page 399: ...eck the fuel tank filler tube cap for malfunction l Check the fuel tank for deformation corrosion or crack l Check the fuel tank for dust or foreign material NOTE If the inside of the fuel tank is to...

Page 400: ...e A bB4 4 High pressure fuel hose connection body side B Bd 5 High pressure fuel hose connection fuel pump side A4 6 Fuel pump and fuel gauge unit assembly REMOVAL SERVICE POINTS A HIGH PRESSURE FUEL...

Page 401: ...then tighten it to the specified torque being careful that the high pressure fuel hose does not become twisted Caution When tightening flare nut be careful not to bend or twist line to prevent fuel p...

Page 402: ...Nm 6 8 ft lbs CT Fuel rail t Removal steps 1 Reserve tank 2 Battery 3 Battery tray with washer tank assembly 4 Purge control valve A 5 Fuel vapor hose 6 Evaporative emission canister 7 Vapor pipe asse...

Page 403: ...1 0 l 2 in B HIGH PRESSURE FUEL HOSE INSTALLATION Apply small amount of new engine oil to the hose union Insert the hose being careful not to damage the O ring and tighten securely Caution Because the...

Page 404: ...the eye bolt while holding the fuel filter nut securely Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line INSTA...

Page 405: ...OLANT TEMPERATURE SWITCH 13 ON VEHICLE SERVICE 4 Cap Pressure Test 4 Engine Coolant Concentration Test 4 Engine Coolant Leak Check 4 Engine Coolant Replacement 4 RADIATOR 5 SPECIFICATIONS 2 General Sp...

Page 406: ...ange of coolant antifreeze concentration Standard value 30 60 Limit Thermostat Valve opening temperature C OF Full opening temperature C F Opening pressure of cap high pressure valve kPa psi 76 5 170...

Page 407: ...reign substance Clean Inoperative electric Faulty coolant temperature sensor Replace cooling fan Up to 1993 models Engine coolant temperature sensor From 1994 models Faulty electrical motor Water leak...

Page 408: ...ul when installing and removing the tester and when testing not to deform the water outlet fitting 4 If there is leakage repair or replace the appropriate part CAP PRESSURE TEST 1 Use a cap adapter to...

Page 409: ...sensor connector Reserve tank Radiator upper hose Radiator lower hose Automatic transaxle oil cooler hoses Vehicles with AIT Condenser fan motor connector Vehicles with air conditioning Condenser fan...

Page 410: ...9 Condenser fan motor connector Vehicles with air conditioning 10 Condenser fan motor assembly Vehicles with air conditioning A4 11 Radiator fan motor connector 12 Therm0 sensor connection For radiato...

Page 411: ...insert into the shroud hole and fix securely INSPECTION l Check for foreign material between radiator fins l Check the radiator fins for bent or damage l Check the radiator for corrosion damage rust o...

Page 412: ...models 1 Immerse the water temperature switch in hot water as shown 2 Change the water temperature and check continuity with a circuit tester If it is as specified below the switch is functioning corr...

Page 413: ...4 Radiator lower hose connection 5 Water inlet fitting 6 Gasket A 7 Thermostat Air intake hose B ZOSFOO23 INSTALLATION SERVICE POINTS A4 THERMOSTAT INSTALLATION Install the thermostat with its jiggle...

Page 414: ...hermostat in container of water Stir to raise water temperature and check that thermostat opening valve temperature and the temperature with valve fully open valve lift over 8 mm 31 in are at the stan...

Page 415: ...Water hose connection Turbo 10 Water outlet fitting 11 Gasket 12 Harness connection 13 Heater hose connection 14 Water hose A connection 15 Water hose connection 16 Water hose connection Turbo 17 Radi...

Page 416: ...to help smooth insertion of the pipe into the water pump thermostat housing Caution Care must be taken not to permit engine oil or other greases to adhere to the O ring C AIR INTAKE HOSE C AIR INTAKE...

Page 417: ...removal and Post installation operation l Engine Coolant Draining and Supplying Refer to GROUP 00 Maintenance Service cup to 1993 models 30 Nm From 1994 models 30 Nm 1 i JdZOlFOO38 Removal steps 1 Air...

Page 418: ...are bottomed INSPECTION ENGINE COOLANT TEMPERATURE GAUGE UNIT Refer to GROUP 54 Meters and Gauges ENGINE COOLANT TEMPERATURE SENSOR Engine control Refer to GROUP 13A MFI System Inspection AIR CONDITI...

Page 419: ...11 26 28 30 33 17 13 15 5 Intake Charge Pressure Control System Check 7 Intake Manifold Vacuum Check Refer to Group 11 Turbocharger Bypass Valve Check 8 Turbocharger Supercharging Pressure Check 6 Tur...

Page 420: ...r head contacting surface mm in Less than 0 15 0059 0 2 008 Turbocharger waste gate solenoid terminal resistance at 20 C 36 44 68 F 2 Turbocharger Supercharging pressure kPa psi Approx 69 10 SPECIAL T...

Page 421: ...e Abnormal noise Probable cause Loose joints Broken pipe or muffler Broken separator in muffler Broken rubber hangers Interference of pipe or muffler with vehicle body Broken pipe or muffler Remedy Re...

Page 422: ...dy 1 Valve Operate valve manually Operates freely Valve sticking Replace main muffler Active Refer to P 1540 exhaust Faulty switch Replace switch switch 3 Power window Check continuity be Continuity p...

Page 423: ...applied to terminals 11 and 12 of the variable induction control motor connector the induction control valve shaft turns smoothly Caution Be sure to apply a voltage of not higher than DC 6V to the var...

Page 424: ...ontinu ity Standard value Measured terminal Continuity Between terminals 11 and Present 12 5 35 Q 20 C 68 F 4 Make sure that when DC 6V is applied to terminals 11 and 12 of the variable induction cont...

Page 425: ...SURE CONTROL SYSTEM CHECK Turbo 1 After the diagnostic trouble code of MFI system is com pletely read turn off the ignition switch 2 Disconnect the hose black from the turbocharger waste gate solenoid...

Page 426: ...r wire B nipple condition Normal condition I Connected Disconnected Open Close Open Negative pressure leaks Negative pressure is held Negative pressure is held COIL RESISTANCE CHECK Measure resistance...

Page 427: ...flow sensor gasket 10 Volume air flow sensor assembly Air intake hose removal steps Non Turbo 11 Breather hose 12 Air intake hose 1 3 R e s o n a t o r 05FOOO1 00000608 Air intake hose removal steps T...

Page 428: ...t air intake hoses B and C until seated Insert the turbocharger end of air intake hoses B and C com pletely INSPECTION l Check the air cleaner body cover or packing for deforma tion corrosion or damag...

Page 429: ...ir hose D 3 Charge air cooler duct RH C 4 Charge air cooler right Charge air cooler left removal steps B 5 Air hose G 6 Air pipe A 7 Heat protector F B 8 Air hose B B 9 Air hose E 10 Air pipe B 11 Air...

Page 430: ...end of air intake hoses B and C com pletely B CHARGE AIR COOLER LEFr AIR HOSE F AIR HOSE E AIR HOSE B AIR HOSE G INSTALLATION Aligning the marks at the points indicated by the arrows insert securely...

Page 431: ...r cable bracket A 4 Throttle body gasket 5 Brake booster vacuum hose connec 14 Intake manifold plenum stay connec tion tion 6 Harness connectors 15 Intake manifold plenum installation bolts 7 VIC moto...

Page 432: ...HROTTLE BODY GASKET INSTALLATION Install with the gasket protrusion positioned as shown Caution If installed in an incorrect direction idling failure or other problems may occur INSPECTION Cheek the f...

Page 433: ...for California 11 Manifold differential pressure sensor From 1996 model 12 EGR valve Up to 1995 model for California and from 1996 model ml IO 3 Nm 05FOO89 0 0 0 0 4 1 5 0 7 9 ft lbs 13 EGR valve gask...

Page 434: ...protrusion positioned as shown Caution L If installed in an incorrect direction idling failure or other problems may occur INSPECTION Check the following points replace the part if a problem is found...

Page 435: ...Refer to GROUP 13F Engine Control l Fuel Leakage Checking lo 13 Nm 8 9 ft lbs q 2 4 ft lbs 5 Nm 1 3 6 24 Nm 17 ft lbs 14 17 ft lbs i 8 x ryLy gg 05FOO24 0 0 0 0 0 6 1 2 Removal steps 1 High pressure f...

Page 436: ...5 Nm 2 2 to 3 6 ftlbs 2 Tighten the nuts in the rear bank to 12 to 15 Nm 9 to 11 ftlbs 3 Tighten the nuts in the front bank to 12 to 15 Nm 9 to 11 ftlbs 4 Repeat steps 2 and 3 one more time respective...

Page 437: ...found INTAKE MANIFOLD CHECK 1 Check for damage or cracking of any part 2 Clogging of the negative pressure vacuum outlet port or clogging of the gas passages 3 Check deflection of installation surface...

Page 438: ...ft lbs 25 05FOO43 0 0 0 0 0 6 1 4 Removal steps D 1 Air hose C E 2 Air intake hose B D 3 Air hose D 4 Air hose A C 5 Air hose B 6 Air pipe B C 7 Air hose E 8 Air pipe C 9 Drive belt Refer to GROUP 11...

Page 439: ...l installation of the turbocharger assembly INSTALLATION SERVICE POINTS bAdTURBOCHARGER ASSEMBLY INSTALLATION Clean the alignment surfaces shown in the illustration Supply clean engine oil through the...

Page 440: ...e arrows insert until seated Insert the turbocharger end of air intake hose 6 completely INSPECTION TURBOCHARGER ASSEMBLYCHECK l Visually check the turbine wheel and the compressor wheel for cracking...

Page 441: ...m 33 ft lbs Removal steps 1 Battery 2 Accelerator cable connection engine side Ed 3 Air hose A Ed 4 Air pipe A 5 Heat protector F 6 Clutch booster vacuum hose 7 Accelerator cable connection pedal 13 E...

Page 442: ...that a piece of the gasket does not enter the oil passage hole B OIL PIPE INSTALLATION Supply clean engine oil through the oil pipe installation hole of the turbocharger assembly C HEATED OXYGEN SENSO...

Page 443: ...the turbine wheel and the compressor wheel can be easily turned by hand l Check for oil leakage from the turbocharger assembly l Check whether or not the turbocharger waste gate valve remains open If...

Page 444: ...moval and Installa tion Vehicles with Air Conditioning Refer to GROUP 14 Radiator 3 12 15 Nm 9 11 ft lbs 30 Nm 22 ft lbs 12 15 Nm 9 11 ft lbs 45 Nm 33 ft lbs Exhaust manifold removal steps front Exhau...

Page 445: ...el 60 Nm 43 ft lbs Up to 1993 models 60 Nm 43 ft lbs 33 ft lbs 12 15 Nm 0 0 0 0 0 6 1 7 Exhaust manifold removal steps front 1 Drive belt Generator Refer to GROUP 11 Service Adjustment Procedures 2 Ge...

Page 446: ...ion Operation l Turbocharger Assembly Removal and Installation Refer to P 1520 23 12 15 Nm 9 11 ft lbs 9 11 ft lbs Exhaust manifold removal steps front 1 Heat protector bC 2 Exhaust manifold front Bq...

Page 447: ...STAY INSTALLATION With the exhaust manifold stay resting on the exhaust man ifold fit it along with the exhaust manifold over the studs Cd EXHAUST MANIFOLD INSTALLATION FRONT Tighten the nuts in the...

Page 448: ...s 1 Main muffler and center exhaust pipe installation bolts 2 Gasket 3 Rubber hanaers 4 Rubber hanker 5 14 Rubber hangers 15 bracket Hanger 16 brackets Hanger 17 Rear floor heat protector 18 6 i 10 11...

Page 449: ...14 Rubber hangers 15 Hanger bracket 16 Hanger brackets 17 Rear floor heat protector 18 Catalytic converter and front exhaust pipe installation bolts 19 Catalytic converter 13 Nm A05F0069 9 ft lbs 20...

Page 450: ...REMOVAL SERVICE POINTS I dAbRUBBER HANGER MAIN MUFFLER REMOVAL Support with a transmission jack etc d INSPECTION l Check the mufflers and pipes for corrosion or damage l Check the rubber hangers for...

Page 451: ...Nm 9 ftlbs 13 Nm 9 ft lbs cOSFOO72 Removal steps 1 Main muffler and center exhaust pipe installation bolts 2 Protector i B 3 Cable assembly connection 4 Rubber hangers 4w 5 Rubber hangers 6 Main muff...

Page 452: ...ket 22 Self locking nuts 23 Rubber hanger 24 Front exhaust pipe 25 Gaskets 26 Self locking nuts 27 Right bank warm up threelway catalytic converter 28 Gasket 29 Hanger bracket B A4 30 Heated oxygen se...

Page 453: ...tch Control l Drive Shaft Left Side Inner Shaft Assembly Removal and Installation Refer to GROUP 26 Drive Shaft 13 Nm 9 ft lbs 3 6 ft lbs 13 13 Nm m 4 n 8 5 Nm 4 ft lbs 13 Nm 9 ft lbs 13 Nm 9 ft lbs A...

Page 454: ...gen sensor protector 23 Heated oxygen sensor connection 24 Self locking nuts 25 Rubber hanger 26 Front exhaust pipe 27 Gaskets 28 Self locking nuts 29 Right bank warm up three way catalytic converter...

Page 455: ...nd Installation l Refer to GROUP 21 Clutch Control Drive Shaft Left Side Inner Shaft Assembly Removal and Installation Refer to GROUP 26 Drive Shaft J 13 Nm 9 ft lbs 37 6 l rl I A 7 x jf 1 3 13 Nm 9 f...

Page 456: ...talytic converter 19 Gasket 20 Oxygen sensor protector 21 Heated oxygen sensor connection 22 Self locking nuts 23 Rubber hanger 24 Front exhaust pipe 25 Gaskets 26 Self locking nuts BO5FOO71 27 Z 4Bb...

Page 457: ...STALLATION SERVICE POINTS A4 HEATED OXYGEN SENSOR INSTALLATION Use the special tool to install the heated oxygen sensor B CABLE ASSEMBLY INSTALLATION Install with the paint mark facing up and adjust t...

Page 458: ...exhaust system control module B1 2 Cable connection Actuator side 3 Actuator 205FOO22 4 Protector A I connection Muffler side INSTALLATION SERVICE POINTS A4 CABLE INSTALLATION Muffler Side Install wi...

Page 459: ...r 1 I Ll t t 7 f t y o 205FOO51 INSPECTION ACTIVE EXHAUST SWITCH CHECK 1 Remove switch garnish B from the knee protector 2 Operate the switch and check the continuity between the terminals Switch posi...

Page 460: ...NOTES...

Page 461: ...ine Coolant Temperature Sensor and intake Air Temperature Sensor 65 CONTINUED ON NEXT PAGE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper servic...

Page 462: ...Non Turbo from 1996 model 67 Mixture Control MFI System 70 Vacuum Control Valve Non Turbo 69 POSITIVE CRANKCASE VENTILATION SYSTEM 56 Component Location 56 Crankcase Ventilation System Inspection 56...

Page 463: ...OR PEDAL Symptom ProbabUe cause Remedy Throttle valve will not Misadjusted accelerator cable fully open or close Adjust Misadjusted automatic speed control cable Adjust Broken return spring Replace Th...

Page 464: ...m 12 20 in 4 If the play is out of the standard limits loosen the adjusting bolts slide the plate so that the inner cable play will fall within the standard limits and then retighten theadjust ing bol...

Page 465: ...celerator cable 5 Accelerator pedal 6 Spring 7 Accelerator switch connector connec 9 Split pin 10 Accelerator arm 11 Return spring 12 Accelerator switch A T 13 Accelerator arm stopper 14 Bolt A T 15 S...

Page 466: ...E AND EMISSION CONTROL Cruise Control System CRUISE CONTROL SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS NOTE l Vehicles built up to April 1991 2 Vehicles built from May 1991 SERVICE SPECIFICATIONS TS...

Page 467: ...SION CONTROL Cruise Control System 17 7 SPECIAL TOOLS Up to 1993 models Checking of the diagnostic output Checking of the diagnostic trouble code Checking of the diagnostic trouble code check harness...

Page 468: ...nsion TROUBLESHOOTING QUICK REFERENCE CHART Cruise control system is canceled when cancellation not wanted Or the cruise control system cannot be set after an automatic cancellation Check the diagnost...

Page 469: ...hen RESUME switch is set to RESUME switch ON Replace control switch OFF code No 22 does not go away P 17 13 malfunction Even when CANCEL switch is set to CANCEL switch ON Replace control switch OFF co...

Page 470: ...rake switch for cruise No 6 canceled when the brake pedal is control malfunction depressed short circuit drive circuit short circuit Remedy Repair the vehicle speed sensor system or replace the part R...

Page 471: ...Malfunction of the ECU Zruise control ON indicator light Burned out indicator light No 3 joes not come on However bulb ruise control is functional Open or short circuit in harness Malfunction of cont...

Page 472: ...it automati cally returns to the neutral position Since the current from switch S2 flows to relay Ryl the contact of relay Ryl remains closed 3 When the main switch is set to OFF current to relay Ryl...

Page 473: ...and neutral position there Battery positive after voltage Main switch OFF and neutral position 0 V thereafter 8 14 Control unit ground 16 Control unit back up power supply At all times At all times o...

Page 474: ...TROUBLESHOOTING HINTS Diagnosis No 15 Automatically canceled ECU terminal voltage to OFF and when the vehicle speed is reduced to less than 40 km h 25 mph the vehicle I will not resume cruising at th...

Page 475: ...tion meter it lights as soon as the main switch is set to ON 2 Cruise control CRUISE indicator light During cruise control operation transistor Trl in the control unit is kept in the ON state to keep...

Page 476: ...the output gear Since the ve hicle speed sensor is of the electronic type the power is supplied through the ignition switch IG TROUBLESHOOTING HINTS Diagnosis No 12 Automatically canceled Kxs5 AK R13...

Page 477: ...LJ ENGINE AND EMISSION CONTROL Cruise Control System 17 17 I 5 Inspection of vacuum pump assembly drive circuit I r Lp s 1 14 21 I 126 J 13 112 V V V 23 ULW AI RlsW YI NO O 48P3d b id TSB Revision...

Page 478: ...f valve and is controlled by the con power to the vacuum pump assembly trol unit as shown in the following table When The vacuum pump assembly consists of a dia the brake pedal is depressed during cru...

Page 479: ...pedal position switch circuit Mm DESCRIPTION OF OPERATION When the clutch pedal is depressed during vehicle speed control the contact of the clutch pedal position switch is closed As a result a cance...

Page 480: ...is placed in the N position during vehicle speed control a cancel signal is input to the control unit which internally interrupts the power supply to the vacuum pump assembly drive circuit for cancel...

Page 481: ...l unit regarding the opening of the accelerator The as well as cruise control closed throttle position switch inputs the data to the control unit on whether or not the accelerator The throttle positio...

Page 482: ...ator pedal switch is used to detect the operating state of the accelerator pedal It is one during vehicle speed control the cruise control unit of the sensors of the ELC 4A T automatic transmis forces...

Page 483: ...e OFF state When the vehicle speed control is in the overdrive This cancels the overdrive mode because no OD mode if the actual vehicle speed falls more than switch ON signal is input to the ELC 4A T...

Page 484: ...iagnostic trouble codes When connecting the scan tool to a vehicle up to 1993 models use the adapter harness supplied together Caution Turn off the ignition switch beforehand whenever the scan tool is...

Page 485: ...s when a scan tool is used From 1994 models Connect a voltmeter to the diagnostic output terminal and the ground terminal of the data link connector using the special tool Observe the voltmeter pointe...

Page 486: ...ostic trouble code first and conduct input check 2 Input check can be conducted by set operations On board diagnostic terminal outputs display patterns 3 Display codes are displayed only if the circui...

Page 487: ...24 and 25 are displayed Vehicle speed less than approx 40 km h 25 mph 26 M T Clutch pedal position Clutch pedal position switch switch ON clutch pedal circuit normal depressed A T Park neutral positio...

Page 488: ...1 16FO256 Engine front view Engine rear view 36FOO60 INSTRUMENT PANEL AND FLOOR CONSOLE 01 02 03 04 05 06 07 08 09 16FO175 Jumper connector Vacuum pump Throttle position sensor Park neutral position s...

Page 489: ...ol relay 15 Over drive switch CA T 16 Cruise control unit 17 Front wiring harness and junction block combination 18 Front wiring harness and junction block combination 19 Front wiring harness and junc...

Page 490: ...30 ENGINE AND EMISSION CONTROL Cruise Control System LOCATION OF CONTROL UNIT AND RELAY 216FO204 L 264 GROUND POINT Engine control module control unit 216FO396 A Ii I T f J c I 2 iFc259 1 TSB Revisio...

Page 491: ...engine and set the ignition switch to OFF 5 Check that the accelerator cable cruise control cable and throttle cable are routed without sharp bends 6 Depress the accelerator pedal to check that the t...

Page 492: ...ith intermediate link C back off adjusting nut B the specified number of turns Amount adjusting nut B is to be backed off About one turn inner cable free travel l 2 mm 04 08 in 7 Secure the throttle c...

Page 493: ...released the constant speed at the time when it was released becomes the driving speed NOTE Even if during acceleration the vehicle speed reaches or exceeds the high limit acceleration will continue...

Page 494: ...H CHECK 1 Remove the main switch together with the switch garnish 2 Remove the main switch from the switch garnish 3 Operate the main switch and check for continuitv across the individual terminals NO...

Page 495: ...spring connector squib connector from the air bag module force the lock outward and pry it with a plain screwdriver as shown at left so that no undue force will be exerted on the connector when it is...

Page 496: ...when the pedal is released PARK NEUTRAL POSITION SWITCH N POSITION CHECK A T 1 Disconnect the connector 2 On 1992 models check to be sure that there is continuity between connector terminals 8 and 9 w...

Page 497: ...olenoid valves are defective replace the vacuum pump assembly Inspection of Motor 1 Disconnect the connector of the vacuum pump assembly 2 Check that when the battery voltage is applied across termina...

Page 498: ...k assembly connection 4 Throttle cable and link assembly connection 5 Vacuum pump connector A4 6 w x wiorose and vacuum pump 7 Link assembly and vacuum pump 8 Vacuum pump 9 Pump bracket 11 07FOO31 000...

Page 499: ...eps 20 Air bag module Refer to GROUP 52B Air Bag Module and Clock Spring 21 Air bag module bracket 22 Cruise control switch 23 Switch garnish 24 Main switch 07FOO28 0 0 0 0 2 4 4 5 Control unit and re...

Page 500: ...eters and Gauges 34 Vehicle speed sensor 3 Refer to GROUP 54 Meters and Gauges 35 Park neutral position switch A T INSTALLATION SERVICE POINT bAdVACUUM HOSE TO VACUUM PUMP CONNECTION Route the vacuum...

Page 501: ...4 at 20 C 68 F Catalytic converter 1 Monolith type Location California Non Turbo up to 1993 model Federal Non turbo UP to 1995 model Under floor Location Turbo California Non Turbo from 1994 model Fed...

Page 502: ...orativ emkm AThrottle body purge solenoid L Light blue R R6d B Black Fuel pressure regulator Federal Non Turbo From 1993 up to 1995 models Evaporative emission purge solenoid Evaporative emission cani...

Page 503: ...low Fuel prkssure regulator Vehicle front 7EM0132 L Light blue R Red 8 Black L California Non Turbo From 1993 up to 1995 models EGR solenoid I I LliLlI FGR al m b n a Evaporative v emission purge sole...

Page 504: ...l System Non Turbo From 1996 models Evaporative emission purge solenoid EGR solenoid valve Evaporative emission canister Throttle body G Green Y Yellow L Light blue R Red B Black W White Fuel pressure...

Page 505: ...lenoid Bypass valve G Green Y Yellow Fuel pressure regulator Purge control valve I Vehicle front L Light blue R Red B Black W White Turbocharger waste gate actuator Turbocharger Turbo From 1993 up to...

Page 506: ...trol System Turbo From 1996 models EVAP purge solenoid PUI C waste gate solenoid TC waste gate Turbocharger I Ucil IJ cJ U r r e g u l a t o r Check valve G Green Y Yellow L Light blue R Red B Black W...

Page 507: ...System VACUUM CIRCUIT DIAGRAM Federal Non Turbo 1992 models 17 47 b Y lntake z num Throes I To combustion chamber From air cleaner B Black L Light blue R Red Fuel pressure regulator EVAP canister EVAP...

Page 508: ...17 48 ENGINE AND EMISSION CONTROL Emission Control System Federal Non Turbo From 1993 up to 1995 models Intake manifold plenum EVAP canister B Black L Light blue R Red 27EM0287 1 TSB Revision...

Page 509: ...ifornia Non Turbo 1992 models Intake manifold plenum Throttle body I To combustion chamber B Black G Green L Light blue R Red Y Yellow Fuel pressure t regulator From air cleaner I G r EGR valve Y 1 A...

Page 510: ...on Turbo From 1993 up to 1995 models Intake manifold plenum Throttle body i To combustion chamber 0 Fuel pressure regulator B Black G Green L Light blue R Red Y Yellow B d EVAP purge solenoid ON open...

Page 511: ...rol System 17 51 Non Turbo From 1996 models take manifold plenum Jp I To combustion chamber a Throttle body I wm17zi imii 1 From G Green Y Yellow L Light blue 6 Red B Black W White Fuel pressure regul...

Page 512: ...1992 models Throttle body To combustion chamber a Fuel pressure regulator TC waste gate solenoid ON open Turbocharger bypass vah Air cleaner EGR valve 12 ao EVAP canister EVAP purge solenoid ON close...

Page 513: ...urbo From 1993 up to 1995 models Intake manifold plenum To combustion chamber Throttle body cd Fuel pressure regulator Turbocharger bypass valve EVAP purge solenoid ON close tii rn I I e n valve I 1 W...

Page 514: ...fold plenum Throttle body F 1 m I1 To combustion chamber II G Green Y Yellow L Light blue R Red B Black W White Fuel pressure regulator IL 13 3 I EGR valve EVAP canister Check valve Air cleaner TC was...

Page 515: ...m that the vacuum hoses are properly connected 2 Check the hoses for irregularities disconnection loose ness etc and confirm that there is no breakage or dam age INSTALLATION 1 When connecting a hose...

Page 516: ...lation valve and check that the negative pressure of the intake manifold is felt with finger NOTE At this time the plunger in the positive crankcase ventila tion valve moves back and forth 3 If negati...

Page 517: ...ission Control System 17 57 EVAPORATIVE EMISSION CONTROL SYSTEM COMPONENT LOCATION Name Symbol Name Symbol Evaporative emission EVAP canister C Purge control valve Turbo B Evaporative emission EVAP pu...

Page 518: ...T Non Turbo From 1993 up to 1995 models Engine control module Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Volume air flow sensor Engine control module Z...

Page 519: ...engine is cold engine coolant temperature 60 C 140 F or less I Engine operating condition Applying vacuum Result I Idling 3 000 mm 375 mmHg 14 8 in Hg Vacuum is main tained When engine is hot engine...

Page 520: ...ne coolant temperature 60 C 140 F or less I Engine operating condition Applying vacuum Result 1 Idling 3 000 mm 375 mmHg 14 8 in Hg Vacuum is maintained When engine is hot engine coolant temperature 7...

Page 521: ...n below check by apply ZFXM0405 ing vacuum from a hand vacuum pump When engine is cold engine coolant temperature 60 C 140 F or less Engine operating condition Applying vacuum Result 3 000 rpm 375 mmH...

Page 522: ...gher Applying vacuum Engine operating condition Result 375 mmHg Idling Vacuum is maintained 14 8 in Hg Sudden racing Vacuum leaks PURGE CONTROL SYSTEM INSPECTION Turbo From 1996 models To air intake h...

Page 523: ...rom the air intake hose and plug the air intake hose Then connect the hand vacuum pump to the purge air hose 6 Apply vacuum in hot engine coolant temperature 70 C 158 F or higher and check to see that...

Page 524: ...VE Turbo INSPECTION 1 Remove the purge control valve of the purge control valve mmHg in Hg airtightness 4 Blow in air lightly from the canister side nipple and check conditions as follows 5 Connect a...

Page 525: ...ard value 36 44 Q at 20 C 68 F VOLUME AIR FLOW SENSOR ENGINE COOLANT TEMPERATURE SENSOR AND INTAKE AIR TEMPERATURE SENSOR To inspect these parts refer to GROUP 13A MFI System Components AIR CONDITIONI...

Page 526: ...STEM COMPONENT LOCATION Name Symbol Name Symbol EGR valve California Non Turbo Turbo Federal Non Turbo from 1996 model S EGR solenoid California Non Turbo Turbo Federal Non Turbo from 1996 model A EGR...

Page 527: ...arm condition of engine Engine operation Normal state Race the engine by rapidly The negative pressure rises to press in the accelerator pedal 100 mmHg 3 9 in Hg or more 3 Disconnect the three way ter...

Page 528: ...passage of the EGR to check condition as follows Applying vacuum Result 45 mmHg 1 8 in Hg or less Air does not blow through 230 mmHg 9 1 in Hg or more Air blows through INSTALLATION Install a new gas...

Page 529: ...ng the vacuum hose make an identification mark on it so that it can be reconnected to the original position 1 cup to 1995 models Disconnect the vacuum hose yellow and green stripe from the solenoid Fr...

Page 530: ...connected 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 Battery voltage B Nipple condition N...

Page 531: ...misfiring occurs Under this condi tion the exhaust system will operate at abnormally high temperature which may cause damage to the catalyst or underbody parts of the vehicle 2 Alteration or deterior...

Page 532: ...NOTES...

Page 533: ...icants 3 CLUTCH MASTER CYLINDER 14 Sealant 3 CLUTCH PEDAL 8 Service Specifications _ 2 TROUBLESHOOTING 3 CLUTCH RELEASE CYLINDER 16 CLUTCH VACUUM LINE VACUUM TANK AWD 18 id ON VEHICLE SERVICE 5 Bleedi...

Page 534: ...Specifications SPECIFICATIONS GENERAL SPECIFICATIONS 225 x 150 8 86 x 5 91 250 x 160 9 84 x 6 30 Clutch booster Boosting ratio Clutch pedal depressing force 1 7 at 110 N 24 Ibs SERVICE SPECIFICATIONS...

Page 535: ...valent TROUBLESHOOTING Symptom Clutch slips Gear shifting failure Probable cause Remedy Clutch pedal play too small Adjust Excessive wear of clutch disc facing Replace Hardened clutch disc facing or o...

Page 536: ...21 4 CLUTCH Troubleshooting Excessive wear of clutch disc facin I LJ 1 TSB Revision...

Page 537: ...ontrol system disconnect the clutch pedal position switch connector and turn the switch for standard clutch pedal height Tighten the lock nut _ to the specified torque Specified torque 13 Nm 9 ft lbs...

Page 538: ...disengages In the case of AWD vehicles measure with the engine running Clearance to toe board when clutch disengages Standard value 55 mm 2 2 in or more 7 If the play and or clearance is out of speci...

Page 539: ...OPERATION CHECK AWD When checking the check valve keep the check valve fit in the vacuum hose 1 Remove the vacuum hose Caution The check valve is press fit inside the vacuum hose and do not remove the...

Page 540: ...dal adjustment Refer to GROUP 35 Service Adjustment Procedures 2 Clutch master cylinder connection 3 Clevis pin 4 Clevis pin 5 Return spring 6 Pedal support bracket Ie i pin 9 Turn over spring 10 Rod...

Page 541: ...2 1 9 33 Bushing 34 Spacer 35 Clutch pedal pad 36 Bolt 37 Lever assembly 38 Bushing 39 Spacer 40 Support bracket 41 Clutch booster 42 Clutch pedal position switch 43 Interlock switch INSPECTION l Che...

Page 542: ...ke booster Refer to GROUP 35 Brake Booster 2 Clevis pin WD 3 Clutch master cylinder bF l Piston adjustment to push rod clearance cAWD 4 Sealer 1 v 208FOO44 00002214 Clutch tube removal steps 1 Brake b...

Page 543: ...D V ZOEFOO45 15 Nm 13 00002215 11 ft lbs Cd Fare pipe AWD 10 Battery seat washer tank C A4 14 Clutch hose Clutch tube A tube B tube C damper removal steps E 5 Air hose A cAWD 6 Air cleaner air intake...

Page 544: ...ER INSTALLATION On AWD vehicles use a flat type short box wrench to tighten the clutch release cylinder mounting bolts Cd VACUUM PIPE AWD INSTALLATION If the vacuum pipe has a stepped part connect the...

Page 545: ...en the clutch booster mounting surface on the master cylinder and the end face 3 Measure the dimension D between the master cylinder mounting surface on clutch booster and the push rod end NOTE To obt...

Page 546: ...hose or tube for cracks or clogging CLUTCH MASTER CYLINDER DISASSEMBLY AND REASSEMBLY FWD Master cylinder kit t 4 Q 8 i EF 10 ES i c 5iR g a 7 g P Ii n 3 Mu 6 ZOBFOO40 13 Nm 9 0 ft lbs 1 A ZOXFOO39 AW...

Page 547: ...the master cylinder body and piston assembly 2 Do not disassemble piston assembly REASSEMBLY SERVICE POINT A PUSH ROD INSTALLATION NOTE Set the push rod length to the dimension shown in the illustrati...

Page 548: ...Conforming to DOT3 or DOT4 6 Conical smina 7 8 Bleeder plug 9 Release cylinder DlSASSEMbLY SERVICE POINT dA PISTON AND CUP DISASSEMBLY 1 Remove the corrosion from the piston removal port of the relea...

Page 549: ...ace of the piston and piston cup and push the piston cup assembly in the cylinder Specified brake fluid Conforming to DOT3 or DOT4 INSPECTION 1 Check the inner surface of the release cylinder for scra...

Page 550: ...heck valve 4 Fitting Vacuum pipe A removal steps Cd 5 Air hose A B 6 Air cleaner cover air intake hose A 7 Vacuum pipe A Vacuum tank assembly vacuum hose E vacuum pipe C removal steps 11 Right member...

Page 551: ...ipe without any stepped part insert the hose until the insertion amount reaches the standard value Standard value 20 25 mm 8 1 0 in BdAIR CLEANER COVER AIR INTAKE HOSE A INSTALLATION Align slots indic...

Page 552: ...Transaxle Assembly Removal Refer to GROUP 22 Transaxle Assembly Post installation Operation l Transaxle Assembly Installation Refer to GROUP 22 Transaxle Assembly 30 42 Nm 1 15 21 Nm ft lbs 2 4Ab C 4A...

Page 553: ...EMOVAL SERVICE POINT Lubricant MITSUBISHI genuine grease Part No 0101011 or eauivalent 6CLO33 ATFM0857 dAbCLUTCH COVER ASSEMBLY CLUTCH DISC REMOVAL Diagonally loosen bolts which attach clutch cover to...

Page 554: ...to the push rod hole in the release fork Specified grease MITSUBISHI genuine grease Part No 0101011 or equivalent B GREASE APPLICATION TO CLUTCH RELEASE BEARING FWD Pack the inner surface of the clut...

Page 555: ...f defective replace the clutch disc Combine the clutch disc with the input shaft and check sliding condition and check for play in the rotating direction If it does not slide smoothly check after clea...

Page 556: ...NOTES...

Page 557: ...CING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injuryordeathtoservi...

Page 558: ...ing to API classifica tion GL 4 As required SEALANTS AND ADHESIVES Items 7 Specrfred sealants and adhesives Transaxle case clutch housing mating surfaces Transaxle case rear cover mating surfaces Diff...

Page 559: ...ten or replace mounts b Inadequate shaft end play b Correct end play c Worn of damaged gears c Replace gears d Use of inadequate grade of oil d Replace with specified oil e Low oil level e Replenish f...

Page 560: ...e 2 Install the grommet so that as shown in the illustration the cable attachment part and the projecting part are horizontal Caution The cable arrangement should be made so that the radius of cable b...

Page 561: ...Refer to GROUP 26 Drive Shaft 2 Using a flat tip screwdriver remove the oil seal 3 Using the special tool tap the drive shaft oil seal into the transaxle The drive shaft oil seal must be installed in...

Page 562: ...0 Nm 2 9 ft lbs 12 Nm 9 ft lbs 5 ZO9FOO79 Transaxle control cable assembly removal steps 1 Air cleaner Air intake hose Shift lever assembly removal steps 1 Air cleaner Air intake hose A 2 Transaxle co...

Page 563: ...of shift lever 3 Install the select cable so that the flange side of the plastic bushing at the end of select cable is on the end face side of lever B 4 Turn adjuster on shift cable so that shift cabl...

Page 564: ...ssembly steps 1 Nut 2 Spring washer 3 Plain washer 4 Shift lever 5 Bushing 6 Plain washer 7 Wave washer 8 Nut 9 Spring washer 10 Plain washer 11 Return spring 12 Bushing 13 Pipe 14 Bolt 15 Lever A 16...

Page 565: ...Service Adjustment Procedures l Shift Lever at Each Position Checking Operation l Meters and Gauges Checking Operation 19 Nm 209FO112 09FOO99 00001532 Removal steps 1 Side under cover 2 Battery 3 Batt...

Page 566: ...all joint connection 15 Right member 16 Starter 4Eb 17 Drive shaft Left side Inner shaft assembly F A 18 Drive shaft Right side 19 Transaxle stay Front bank side 4G 4Gb 20 Transaxle stay Rear bank sid...

Page 567: ...BALL JOINT DISCONNECTION Using the special tool disconnect the lower arm ball joint from the knuckle Caution 1 Be sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but do n...

Page 568: ...ER PART COUPLING BOLT TRANSAXLE ASSEMBLY REMOVAL Support transaxle assembly with a transaxle jack and remove transaxle assembly lower part coupling bolt then lower trans axle assembly INSTALLATION SER...

Page 569: ...D999563 Oil pressure gauge 10 kg cm2 H MD998332 MD998332 01 Connection of the oil pressure gauge Adapter 3 A MD99891 5 MD99891 6 01 Adjustment of kickdown servo MD99891 6 l 01 A Kickdown servo wrench...

Page 570: ...22 14 MANUAL TRANSAXLE AWD Special Tools SPECIAL TOOLS Oil seal installer TSB Revision...

Page 571: ...enance Service 22 15 R H side For L H Dust seal For R H DRIVE SHAFT OIL SEALS REPLACEMENT 1 Disconnect the drive shaft from the transaxle Refer to GROUP 26 Drive Shaft 2 Remove the transfer assembly 3...

Page 572: ...rm ing to API classification GL 4 TRANSFER OIL SEAL REPLACEMENT 1 Pull out the propeller shaft from the transfer Refer to GROUP 25 Propeller Shaft 2 Using a flat tip screwdriver remove the oil seal 3...

Page 573: ...ransaxle controll cable assembly removal steps Dd 1 Air hose A Cd 2 Air cleaner cover Air intake hose A Bd 3 Vacuum pipe A 4 Transaxle control cable assembly connection Shift lever assembly side 5 Ret...

Page 574: ...ts indicated by arrows in air intake hose A with A markings on air intake hoses B and C then insert hoses B and C all the way into air intake hose A DqAIR HOSE A CONNECTION Connect the hoses ensuring...

Page 575: ...llation Refer to P 22 22 l Transmission Oil Supplying Refer to l 22 15 l Shift Lever at Each Position Checking Operation l Meters and Gauges Checking the Operation c Hose clamp 4 0 Nm 09FOllO 00001537...

Page 576: ...5 Mounting stopper 16 Transaxle mount bracket Transaxle side 17 Transaxle assembly lower part 4B coupling bolt 18 Tie rod end connection 4B 19 Lower arm ball joint connection 20 Right member 6 21 Star...

Page 577: ...VACUUM PIPE INSTALLATION If the vacuum pipe has a stepped part connect the vacuum hose to the pipe securely up to the stepped part as shown in the figure C AIR CLEANER COVER AIR INTAKE HOSE A INSTALLA...

Page 578: ...leeve yoke lOG0001 Gear oil Hypoid gear oil SAE 75W 90 or 75W 85W conforming to API classifi Removal steps 1 Bolts and nuts 2 Gaskets 3 Warm up catalytic converter and front exhaust pipe 4 Transfer as...

Page 579: ...below are defective replace the transaxle assembly REPLACEMENT PART ZfFM0157 1 Transfer mounting bolts D 5 Input shaft rear seal cap Fd 2 Transfer case oil seal C 6 Center shaft oil seal E 3 Transfer...

Page 580: ...the illustration drive the oil seal until it is flush with the case Do not drive the oil seal more than necessary DdlNPUT SHAFT REAR SEAL CAP INSTALLATION Using the special tool install the input sha...

Page 581: ...pection of Electronic Control System Components 32 Shift Patterns 29 Transaxle Control Module 27 Troubleshooting Guide 15 WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEH...

Page 582: ...i...

Page 583: ...brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutch soieno d 12 Reducing valve...

Page 584: ...I di...

Page 585: ...rake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutch solenoid 12 Reducing valve 1...

Page 586: ......

Page 587: ...h t Rear clutch 5 Low reverse brake End clutch 7 Kickdown servo 8 Transaxle control module Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve Torque converter clutch sole...

Page 588: ......

Page 589: ...22 23 24 25 26 End clutch valve Torque converter control valve Shift control solenoid valve B Shift control valve N D control valve Regulator valve Manual valve Pressure control valve N R control valv...

Page 590: ......

Page 591: ...rse brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 Z 3 4 3 shift valve Il Torque converter clutch solenoid 12 Reducing va...

Page 592: ......

Page 593: ...2 Front clutch 3 Rear clutch 16 Torque converter control valve 17 Shift control solenoid valve B 4 Low reverse brake 18 Shift control valve 5 End clutch 19 N D control valve 6 Kickdown servo 20 7 Tran...

Page 594: ......

Page 595: ...r clutch 4 Low reverse brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve IO 2 3 4 3 shift valve 11 Torque converter clutch sole...

Page 596: ......

Page 597: ...3 Rear clutch 4 Low reverse brake 5 End clutch 6 Kickdown servo 7 Transaxle control mod ule 8 Torque convertor clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutc...

Page 598: ......

Page 599: ...h 4 Low reverse brake 5 End clutch 6 Kickdown servo 7 Transaxle control module 8 Torque converter clutch valve 9 Rear clutch exhaust valve 10 2 3 4 3 shift valve 11 Torque converter clutch solenoid 12...

Page 600: ...I I I LJ LJ I L...

Page 601: ...l at 20 C 68 F Up to 1993 model Q Specifications Approx 3 Resistance of torque converter clutch solenoid valve coil at 20 C 68 F From 1995 model Q Approx 13 Line pressure Line pressure kPa psi Oil pre...

Page 602: ...lubricants DIAMOND ATF SP or equivalent Quantity 7 5 7 9 As required SPECIAL TOOLS and lower arm ball joint l Disconnection of thecoupling of the knuckle and tie rod end ball joint ecking of the diagn...

Page 603: ...I 4th 1 0 823 0 918 I Reduction ratio 6th Reverse Primary 0 589 3 076 3 153 1 375 1 222 Front differential 2 888 3 166 Transfer 0 814 0 958 Speedometer gear ratio driven drive 27136 28136 Oil quantit...

Page 604: ...related to the valve body check the hydraulic pressure oassaaes for leakaae etc If the problem is unusually dirty ATF abnormal noises oil leakage or slippage of the clutch or brakes or an abnormalcon...

Page 605: ...19 0 ring of low reverse brake circuit between valve body and case notinstalled I I X I 20 Malfunction of end clutch or piston check ball hole other 21 Malfunction of park neutral position switch dama...

Page 606: ...ff Engine stalls Clutch slips at Clutch slips at Enginestarts when Stall rpm Vehicle D stall rpm too or vehicle Parking Abnormal N DorR R stall rpm too moves vibration shock high too low moves doesn t...

Page 607: ...AUTOMATIC TRANSAXLE Troubleshooting 23 17 Won t shift from Won t shift to 4th xcessive creep I I I I 37 X X X X X X X TSB Revision...

Page 608: ...23 18 AUTOMATIC TRANSAXLE Troubleshooting Excessive vibration shock during upshift TSB Revision...

Page 609: ...AUTOMATIC TRANSAXLE Troubleshooting 23 I 9 L L 1 TSB Revision...

Page 610: ...per filling can also raise fluid level too high When transaxle has too much fluid gears churn up foam and cause same conditions which occur with low fluid level resulting in accelerated deterioration...

Page 611: ...chart 4 After turning the ignition switch once to OFF turn it back to ON When using a voltmeter cl993 model 1 Connect an analog voltmeter to the diagnostic output terminal No 6 terminal and the groun...

Page 612: ...ol is used METHOD OF ERASE THE DIAGNOSTIC TROUBLE CODES When using the scan tool Multi use tester MUT cup to 1993 model or MUT II All models 1 Turn the ignition switch to OFF and then back to ON again...

Page 613: ...ted or improperly adjusted accelerator l Check accelerator switch connector switch l Check accelerator switch on bench cl 992 model only l Adjust accelerator switch Open circuited pulse generator A l...

Page 614: ...erators A and B on bench l Front clutch slipping l Rear clutch slipping l Check connectors of pulse generators A and B l Check pulse generators A and B on bench l End clutch slipping l Kickdown brake...

Page 615: ...rator pedal cable is defective if change is not smooth Equivalent to out l Defective oil temperature sensor or side temperature circuit harness Gradually increases After engine warming up L range idle...

Page 616: ...h or circuit harness l Defective manual control cable If selector lever does not move check shift lock mechanism Vehicle speed reed D Data list D Item No 38 l Duty should become 100 when ac D range ge...

Page 617: ...elay signal 7 Engine communication signal 8 Diagnostic test mode control terminal 9 Engine communication signal 10 Power source backup 11 Kickdown servo switch 12 Closed throttle position switch 13 14...

Page 618: ...ngine communication signal 18 Engine communication signal 19 20 Closed throttle position switch ZTFA0744 Throttle position sensor TPS 23 Oil temperature sensor 24 Sensor ground 25 Power source 26 Grou...

Page 619: ...ntrol unit of this transaxle One is the power pattern for more powerful perfor mance and the other is the economy pattern for improved fuel consumption and quieter operation The driver can select and...

Page 620: ...rspeed rpm I I I I I I I I I I I I I I I 1 I I I I 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Vehiclespeed km h ZTFA0570 100 I i I I J I I I _ 80 I I I 60 40 3 4ol i 1 27 I ii 20...

Page 621: ...L I 1 I 1 1 1 1 I 1 1 1 I 1 I 1 I 1 c 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Vehicle speed km h ZTFA0817 L E range I I Ii I 11 I I 1000 2000 3000 4000 Transferdrivegearspeed...

Page 622: ...ngcon nection 1 Reconnecttheconnector repair or replace the harness 1 Low temperature side 2 Ground 3 High temperature side 3 Oil temperature Vatythethermo sensitivepartfromlowtempera sensor ture to h...

Page 623: ...the resistance between terminals 4 and w Resistance more or 2 with the engine idling after throttle valve open less than 0 4 kW2O C ing warm up 68 F 1 Readjust the TPS installation 1 Resistance approx...

Page 624: ...n of the age waveform between terminals 1 and 2 pulse generator I I Oscilloscope waveform tion or replace the pulse gener Improper grounding of the pulse generator circuits shielded wir 1 ins I TFA132...

Page 625: ...operation noise stroke 0 3 mm 012 in or less tween the valve and guide 4 Noise exists Replace the PCSV Normal 8 Shift control solenoid valve SCSV A or B Check the resistance between terminal 3 or 4 o...

Page 626: ...rake firmly Let the engine continue idling Normal Improper adjustment of idling I f Readjust the idling c d Poor closure sticking of the torque converter clutch solenoid I Replace the torque converter...

Page 627: ...itch ON and OFF and check operation Check for sticking l Foreign terminal caught be for operation noise Valve stroke in or tween the valve and guide i less I Noise exists Sticking is usually 1 Replace...

Page 628: ...11 21750339 I I Continuity exists In the N range check for continuity between terminals 2 and 4 and terminals 8 and 9 In the D range check for continuity between ContinuiD exists 1 In the 2 range che...

Page 629: ...he R range check for continuity between terminals 2 and 3 and terminals 5 and 6 1 Continuity exists 1 In the D range check for continuity between terminals 3 and 10 1 Continuity exists In the 2 range...

Page 630: ...or continuity between the kickdown servo switch terminal and the Continuity exists 1Poor contact sticking I t No continuity J Normal 15 Transaxle control module Disconnect the harness both A and B con...

Page 631: ...C PRESSURE TABLE No Conditions Standard oil pressure kPa psi W W Select Engine Gear a IUD brake CC Cd W 9 WD brake Front Rear 0 Low re Torque lever speed Reducing pressure End clutch verse converter p...

Page 632: ...15 of input shaft Defective torque converter Remedy Visually check oil filter and replace it if plugged Measure line pressure b K D brake pressure and readjust line pressure if it is out of specifica...

Page 633: ...ina l 5 Seal ring I ii 7 Seal ring 14 O ring I 4 D ring 6 D ring 12 Oil seal D ring 8 Seal ring 15 Seal ring Y Rear clutch 13 Front clutch O ringI End tch 10 SeaI ring L Low reverse brake 1 Seal ring...

Page 634: ...l test is required operate engine at approximately 1 000 rpm in neutral for 2 minutes to cool transmission fluid between tests Stall speed 2 200 3 200 rpm TRANSAXLE CONTROL Symptom Selector lever oper...

Page 635: ...and Check and adjust lock cams A 23 59 B and B Improperly adjusted shift lock cable elon Check adjust and replace shift 23 56 gated inner cable lock cable Sticking slide lever and cam lever inside ke...

Page 636: ...ck slide lever 23 56 Ignition key can be Damaged lock cam A turned to LOCK posi Check and replace lock cam A 23 59 tion even with selec Loose key cylinder cover Check and retighten cover 23 56 tor lev...

Page 637: ...on Caution 1 Do not push piston with the special tool 2 Secure adapter only hand tight to L R brake pres sure take up port and do not apply excessive torque 4 Loosen lock nut to immediately before V g...

Page 638: ...orque wrench could result in lock nut being turned with adjust rod 9 Remove the special tool to secure the piston and torque plug to specification at UR brake pressure take up port LINE PRESSURE ADJUS...

Page 639: ...gth 25 mm 98 in Bolt C Length 40 mm 1 57 in Caution Secure solenoid valve and oil temperature sensor harness at locations shown Especially the pressure control solenoid valve PCSV harness must be rout...

Page 640: ...oil pan 4 Perform hydraulic test Adjust as necessary When scan tool is used 1 Use scan tool to measure the K D brake apply pressure when the pressure control solenoid valve is force driven at 50 duty...

Page 641: ...o be sure the selector lever can be shifted to each position by button operation as shown in the illustra tion 3 Start the engine and check if the vehicle moves forward when the selector lever is shif...

Page 642: ...gnition key to the LOCK position 4 Loosen nut that secures key interlock cable 5 Lightly pressing lock cam A in the direction of arrow lightly push key interlock cable to take up slack and tighten nut...

Page 643: ...n illustration on left of manual control lever is aligned with the hole in park neu tral position switch body flange 5 Tighten the mounting bolts of the park neutral position switch body to the specif...

Page 644: ...the adapter into the instrument panel and fasten the new speedometer cable 2 Install the grommet so that as shown in the illustration the cable attachment part and the projecting part are horizontal...

Page 645: ...OO31 Transaxle control cable removal steps 1 Air cleaner cover Air intake hose C 4 Transaxle control cable assembly connection Select lever assembly side 5 Transaxle control cable assembly 6 Clamp 7 A...

Page 646: ...rotector Refer to GROUP 52A Instrument Panel 11 Column cover lower 12 Cover B 13 Cam lever B 14 Key interlock cable B 15 Slide lever 16 Cable guide 17 Clamp 09FOO35 00001854 Shift lock cable removal s...

Page 647: ...ustment 1 Place the selector lever in N position 2 Loosen the nut and slightly pull the transaxle control cable in the direction of the arrow then tighten the nut DdSHlFT LOCK CABLE CONNECTION SELECTO...

Page 648: ...MBLY SIDE 1 Place the selector lever into P position 2 Connect the key interlock cable to lock cam A and temporarily tighten the nut At this time install the spring and washer which have been fitted t...

Page 649: ...nomy ECO Hold HOLD changeover switch connector 2 Cover 3 Selector knob 4 Overdrive control switch button 5 Overdrive control switch 6 Pin 7 Pushbutton 8 Spring 9 Indicator panel 10 Power PWR Economy E...

Page 650: ...overdrive control switch button 2 Remove the overdrive control switch mounting screw 3 Pressing the switch remove the overdrive control switch REASSEMBLY SERVICE POINT A SLEEVE INSTALLATION Place the...

Page 651: ...OFF 6 RW Bw i 09FOO99 09FO101 00001858 OVERDRIVE CONTROL SWITCH CHECK Check for continuity between terminals when the switch is OFF and when ON 1 Switch position Terminal No I I I 1 ON Overdrive activ...

Page 652: ...OUP 51 Front Bumper Vehicles with oil cooler 12 Nm 9 ft lbs 4 0 2 9 N m 10 ft lbs q 30 35 Nm 22 25 ft lbs 4 0 Nm 2 9 ft lbs 09FO 16 00001859 4Ab t 4Ab 4Bb 1 Hose 2 Tube assembly 3 Feed hose 4 Return h...

Page 653: ...AL 1 Wipe the connection threads and tightly contacting surfaces clean of dust and dirt 2 Secure the oil cooler connector with a spanner to prevent excessive force from being applied to it then loosen...

Page 654: ...aintenance Service l Selector Lever Operation Check 0 Speedometer Operation Check 51 ft lbs m 70 Nm 51 ft lbs ZOSFO112 OSFOO61 00001860 Removal steps 1 Side under cover 2 Battery 3 Battery seat Washer...

Page 655: ...rive shaft right side 21 Transaxle stay front bank side 22 Transaxle stay rear bank side 23 Bell housing cover 24 Special bolts 25 Transaxle assembly lower part coupling bolt 4D A 26 Transaxle assembl...

Page 656: ...al bolts push the torque converter toward transaxle so that it does not remain on the engine side 4 Remove coupling bolt at the bottom of transaxle assembly and lower the transaxle assembly INSTALLATI...

Page 657: ...PROPELLER SHAFT CONTENTS PROPELLER SHAFT 3 General Specifications 2 SPECIAL TOOL 3 Lubricants 2 Service Specifications 2 SPECIFICATIONS 2 Adhesive TROUBLESHOOTING 2 3...

Page 658: ...joint O D Specifications Cross type Cross type Constant velocity type Cross type Pre packed type 16 63 99 73 3 93 NOTE Propeller shaft length indicates the length between the center points of each joi...

Page 659: ...mptom Probable cause Remedy Noise at start Noise and vibration at high speed Worn journal bearing Worn sleeve yoke spline Loose propeller shaft installation Unbalanced propeller shaft Worn journal bea...

Page 660: ...serted in the boot 2 Use the special tool provided as a cover to prevent the entry of foreign objects into the transfer B SPACER REMOVAL The number of spacers necessary may differ from one location to...

Page 661: ...yokes for wear damage or cracks l Check the propeller shaft for bends twisting or damage l Measure the propeller shaft runout with a dial indicator Limit Front propeller shaft 0 6 mm 024 in or less Ce...

Page 662: ...0 0 1 0 2 6 Adhesive 3M ATD Part No 8155 or equivalent 9 Rubber packing B 10 Lobro joint boot 11 Washer 4Fb 12 Center propeller shaft A 13 Self locking nut G A 14 Companion flange H A 15 Center beari...

Page 663: ...the companion flange and the center propeller shaft before removing the companion flange C CENTER BEARING ASSEMBLY REMOVAL First remove the center bearing bracket and then remove the center bearing u...

Page 664: ...y available NOTE When changing the grease on the Lobro joint assembly wipe off the grease and clean the outer and inner races cage and balls 4 If the outer race cannot be removed remove the complete L...

Page 665: ...the companion flange B LOBRO JOINT BOOT INSTALLATION Tape the serration of the center propeller shaft and then install the Lobro joint boot Cq L6BRO JOINT ASSEMBLY INSTALLATION Assemble the Lobro join...

Page 666: ...three locations illustrated to prevent displacement of the rubber packing and fix it to the Lobro joint assembly temporarily Specified adhesive 3M ATD Part No 8155 or equivalent 8 Lining up the mating...

Page 667: ...he Lobro joint assembly and the companion flange F CENTER BEARING ASSEMBLY COMPANION FLANGE SELF LOCKING NUT INSTALLATION 1 Install the bearing in the rubber mount groove of the center bearing bracket...

Page 668: ...NOTES...

Page 669: ...AXLE CONTENTS DRIVE SHAFT 12 HUB AND KNUCKLE 6 ON VEHICLE SERVICE 5 SPECIFICATIONS 2 General Specifications 2 Lubricants 2 Service Specifications 2 Hub End Play Check 5 TROUBLESHOOTING 5 SPECIAL TOOL...

Page 670: ...1 77 DRIVE SHAFT Items FWD AWD Joint type Length mm in Outer Inner L H shaft R H shaft B J T J 417 16 4 405 15 9 or 393 15 5 B J T J 419 16 5 391 15 4 NOTE Al r SERVICE SPECIFICATIONS Items Setting of...

Page 671: ...IAL TOOLS A MB990244 Preload socket rement of the lower arm ball joint starting ment of the stabilizer link rotation Press out of the center bearing Press fitting of the center bearing Press fitting o...

Page 672: ...90890 01 Press fitting of the dust seal Rear suspension Press fitting of the wheel bearing oil seal drive shaft side bushing base MB990883 MB990883 01 Fate suspension MB990947 4 ki i bor MB990947 01 P...

Page 673: ...eplace Broken boot grease leakage Replace repack grease Bend damage or abnormal wear of drive shaft Replace Play of drive shaft and hub serration Replace Abnormal wear play or seizure of center bearin...

Page 674: ...bs r llFO026 00000628 Removal steps 4Ab 1 Front speed sensor connection Vehicles with ABS A 2 Cotter pin I A 3 Drive shaft nut 4 5 Callper assembly Brake disc 6 Front hub unit bearing 7 Dust shield 4D...

Page 675: ...icle temporarily secure the wheel bearing by using the special tools MB990998 etc C CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it with wires AD LOWER ARM BALL JOINT DISCONNECTION...

Page 676: ...wear l Check the oil seal for damage l Check the knuckle for cracks l Check for defective bearing NOTE If the meshing of the wheel bearing outer race and the knuckle or of the wheel bearing inner rac...

Page 677: ...h ABS llLO125 211 A0281 DISASSEMBLY SERVICE POINTS A HUB AND ROTOR REMOVAL 1 Attach the special tools to the knuckle and front hub 2 Secure the knuckle in a vise 3 Tighten the nut of the special tool...

Page 678: ...grease 2 Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces 3 With the wheel bearing inner race removed press in the bearing by using the special tools 4 Install t...

Page 679: ...6 If the starting torque and hub end play are not within the limit range while the nut is tightened to 200 260 Nm 145 188 ftlbs the bearing hub and or knuckle have probably not been installed correctl...

Page 680: ...bracket installation bolt 7 Drive shaft and inner shaft assembly L H 8 Drive shaft R H 9 Circlip Caution In the case of AWD vehicles with ABS take care not to damage the rotor for ABS installed to the...

Page 681: ...e sure to tie the cord of the special tool to the nearby part 2 Loosen the nut but do not remove it D DRlVE SHAFT AND INNER SHAFT FokllLY L H DRIVE SHAFT R H 1 Using the special tool push out the driv...

Page 682: ...hicle to the ground and finally tighten the wheel bearing nut 3 If the position of the cotter pin holes does not match tighten the nut up to 260 Nm 188 ftlbs in maximum 4 Install the cotter pin in the...

Page 683: ...and inner shaft T J case Seal plate Inner shaft Dust shield Bracket assembly Dust seal outer Dust seal inner Center bearing Center bearing bracket Circlip 00000632 Bracket Assemblv Bearing Dust Seal R...

Page 684: ...respectively at the joint and inside the boot Special grease is used to lubricate the joint Do not mix old and new grease or different types 1 of grease Grease Repair kit grease cFWDr 145 g 5 11 oz cA...

Page 685: ...erneath 2 Use the special tool to remove the inner shaft from the center bearing bracket B CENTER BEARING REMOVAL Use the special tools to remove the center bearing from the center bearing bracket C T...

Page 686: ...grease is used to lubricate the joint Do not mix old and new grease or different types of grease 3 Secure the boot bands Caution 1 The boot bands should be tightened with the drive shaft at a 0 joint...

Page 687: ...bearing bracket DA DUST SEALS INSTALLATION 1 Apply multipurpose grease to the rear surfaces of all dust seals Dust seal inner 14 20 g 49 71 oz Dust seal outer 8 12 g 28 42 oz 2 Press the oil seal into...

Page 688: ...press the seal plate into the T J case 3 Fill the specified grease furnished in the repair kit to the T J case Specified grease Repair kit grease 160 g 5 64 oz Caution 1 The grease in the repair kit...

Page 689: ...Check the dust cover for damage or deterioration 1 11X0138 r MB991561 Stopper 1x0131 Adjusting bolt 11x0141 00003420 B J BOOT RESIN BOOT REPLACEMENT 1 Remove the large and small boot bands NOTE Do no...

Page 690: ...mount of crimping is above 2 8 mm llO in Readjust W given in 4 above to the value calculated by the following formula and repeat work described in 6 W 5 5 mm 217 in B Example When B mm 102 in 2 9 mm 1...

Page 691: ...14 Make sure that the amount of boot band crimping is within the range of standard value E Standard value E 2 4 2 8 mm 094 110 in When amount of crimping is above 2 8 mm llO in Readjust W given in 11...

Page 692: ...NOTES...

Page 693: ...el Bearing End Play Check 14 Rear Wheel Bearing Rotary Sliding Resistance Check 15 SPECIAL TOOLS 8 SPECIFICATIONS 6 General Specifications 6 Lubricants 7 Sealants and Adhesives 7 Service Specification...

Page 694: ...SPECIFICATIONS d GENERAL SPECIFICATIONS Item Specification Wheel bearing Type Unit ball bearing SERVICE SPECIFICATIONS Items Limit Wheel bearing end play mm in 0 05 002 or less Rear hub rotary slidin...

Page 695: ...ace the rear hub bearing unit if an adjustment cannot be made to within the limit REAR HUB ROTARY SLIDING RESISTANCE CHECK 1 Inspect the play of the bearings while the vehicle is jacked up and resting...

Page 696: ...Rear rotor Vehicles with ABS 9 Rear hub unit bearing Caution Rear hub unit bearing cannot be disassembled REMOVAL SERVICE POINTS A REAR SPEED SENSOR REMOVAL VEHICLES WITH ABS Caution Be careful when...

Page 697: ...nd not to drop it If the rotor s toothed surface is chipped or the rotor is deformed it might not be able to accurately sense the wheel rotation speed and the system as a result might not perform norm...

Page 698: ...Hypoid gear Up to 1993 models 3 545 From 1994 models 3 307 Differential gear type Side gear and configuration Pinion gear Number of teeth Drive gear Drive pinion Side gear Pinion gear 1 O D x I D mm...

Page 699: ...25 l 2 gear oil application Rear wheel bearing rotation torque N Ibs I 12 2 6 I Rear axle total backlash mm in Drive gear runout mm in 5 2 I 1 0 05 002 Rear wheel bearing end play mm in I I 0 8 031 I...

Page 700: ...of axle shaft inner bearing Installation of axle shaft inner bearing Installation of drive pinion rear bearing outer race Installation of drive pinion front bearing outer race Installation of differen...

Page 701: ...r gauge MB990802 MB990802 01 Pressing of drive pinion rear bearing inner race Pressing of side bearing inner race Bearing installer MB990326 General tool service Measurement of the drive pinion preloa...

Page 702: ...eral service tool General service tool MB991367 01 P 334 MB990339 01 MB990811 01 MIT44801 MIT303173 MB990767 01 Application Driving out and press fitting of differential support bushing and differenti...

Page 703: ...Application MB990339 General service Removal of drive pinion rear bearing inner race Taper roller bear tool ing puller MB990648 General service Bearing remover tool MB990890 MB990890 01 Press fitting...

Page 704: ...er components abnormal noise can also be caused by the universal joint of the propeller shaft the axle shafts the wheel bearings etc Before disassembling any 2 2 parts take all possibilities into cons...

Page 705: ...ufficient gear oil quantity Replenish Breakdown 2 Incorrect final drive gear backlash Adjust Insufficient drive pinion preload Insufficient side bearing preload Excessive differential gear backlash Lo...

Page 706: ...ve the differential carrier assembly and adjust the backlash Refer to P 27 27 GEAR OIL LEVEL CHECK 1 Remove the filler plug and check the oil level 2 The oil level is sufficient if it reaches the fill...

Page 707: ...ary sliding resistance exceeds the limit value check the tightening torque of the axle shaft companion flange If it is normal replace the bearing LIMITED SLIP DIFFERENTIAL CHECK 1 Block the front whee...

Page 708: ...7 Companion flange 4W 8 Axle shaft assembly dE F 9 Rear rotor Vehicles with ABS 4F FE 10 Outer bearing F D 11 Dust shield C 12 Dust shield 13 Axle shaft 4G B 14 Oil seal G A4 15 Inner bearing REMOVAL...

Page 709: ...AL With the special tool remove the axle shaft from the axle housing E REAR ROTOR REMOVAL VEHICLES WITH ABS Using the special tool remove the rear rotor from the axle shaft dF OUTER BEARING DUST SHIEL...

Page 710: ...SHIELD INSTALLATION Orienting the dust shield as shown in the illustration and using the special tool press fit the dust shield until it contacts the axle shaft shoulder NOTE When tapping the oil sea...

Page 711: ...al tool secure the axle shaft and tighten the companion flange self locking nut INSPECTION l Check the companion flange for wear or damage l Check the dust shield for deformation or damage l Check the...

Page 712: ...uipped with the LSD having a VCU has a two part serration Be very careful to install each one on the correct side NOTE The left and right drive shafts can also be distinguished from each other by the...

Page 713: ...1 lN0023 B J repair kit P i 1 2 c f g llNO024 0 0 0 0 1 0 4 6 T J repair kit llN0022 Disassembly steps C 1 T J boot band large C 2 T J boot band small 3 T J case 4W 4 Snap ring A FBI 5 Spider assembl...

Page 714: ...to each as a rule Special grease is used for the joint Do not mix old grease with new or mix different types llA0369 Grease Repair kit grease Quantity to use 125 g 4 41 oz Caution Apply all of the gr...

Page 715: ...t the T J and B J boots are not damaged when they are removed 2 Withdraw the T J and B J boots from the drive shaft C GREASE FROM B J REMOVAL Wipe out the grease from the B J Caution Do not disassembl...

Page 716: ...d grease Repair kit grease 2 Install the spider assembly with the chamfered spline end first C T J BOOT BANDS INSTALLATION Set the T J boot bands at the specified distance in order to adjust the amoun...

Page 717: ...aintenance Service l Main Muffler Removal and Installation Refer to Group 15 Exhaust Pipe and Muffler 24 Nm 17 ft lbs 6 90 Nm 90 Nm 65 ft lbs L 22 25 ft lbs 90 Nm 65 ft lbs Removal steps A 1 Drive sha...

Page 718: ...er shaft connection 3 Support the propeller shaft with wire C DIFFERENTIAL CARRIER REMOVAL Holding the bottom of the differential carrier and removing the rear wheel oil pump through the mounting hole...

Page 719: ...ools in a vice and attach the differential carrier to the working base FINAL DRIVE GEAR BACKLASH CHECK With the drive pinion locked in place measure the final drive gear backlash with a dial indicator...

Page 720: ...on and then once in the reverse direction while applying a load to the drive gear so that the revolution torque approximately 2 5 3 0 d Nm 28 33 in lbs is applied to the drive pinion Caution If the dr...

Page 721: ...pattern resulting from insufficient pinion height The drive pinion is positioned too close to the center of the drive gear Decrease the thickness of the pinion height adjusting shim and position the...

Page 722: ...earing inner race 9 Drive gear for 4WS 10 Drive gear 11 Spring pin for 4WS 12 LSD case Refer to P 27 40 13 Self locking nut 14 Washer 4F 15 Drive pinion assembly 16 Companion flange 17 Drive pinion fr...

Page 723: ...mm 39 in wide and 1 to 2 mm 04 to 08 in high made of copper sheet or the like to prevent damage to the bearing C SlDE BEARING INNER RACES DRIVE GEAR FOR 4WS REMOVAL Pull out the side bearing inner rac...

Page 724: ...special tools H OIL SEAL DRIVE PINION FRONT BEARING REMOVAL Using the special tool drive out the drive pinion front bearing from the gear carrier I DRIVE PINION REAR BEARING OUTER RACE REMOVAL Using...

Page 725: ...n rear bearing inner race Drive pinion spacer Drive pinion preload adjustment Drive pinion front shim Drive pinion assembly Drive pinion front bearing inner race Oil seal Companion flange Aen I YllFOO...

Page 726: ...dhesive 3M Stud Locking Part No 4170 or equivalent Spring pin Drive gear I REASSEMBLY SERVICE POINTS bAdSPRING PIN INSTALLATION FOR 4WS Tap the spring pin into the differential case to the position sh...

Page 727: ...e outer race at an angle D DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures 1 Install special tools and drive pinion front and rear bearing inner races on the...

Page 728: ...front shim s between the drive pinion spacer and the drive pinion front bearing inner race 2 Tighten the companion flange to the specified torque by using the special tools NOTE Do not install the oi...

Page 729: ...al tools 6 fvleasure the drive pinion rotation torque with oil seal to verify that the drive pinion rotation torque complies with the standard value Standard value Bearing classification Bearing lubri...

Page 730: ...side bearing inner races to the differential case by using the special tool H FINAL DRIVE GEAR BACKLASH ADJUSTMENT 1 Using the special tool temporarily tighten the side bearing nut until it is in the...

Page 731: ...Check the drive gear and drive pinion for tooth contact If poor contact is evident make adjustment Refer to P 27 29 7 Measure the drive gear runout at the shoulder on the reverse side of the drive ge...

Page 732: ...tial side gear R H 9 Thrust washer R H A4 10 Differential case B BEFORE DISASSEMBLY CHECK DIFFERENTIAL GEAR BACKLASH CHECKING 1 Secure the differential case assembly in a vise so that the differential...

Page 733: ...n the standard value range the backlash of the differential gear is normal 6 If the clearance in the thrust direction of the side gear is not within the standard value range remove differential case A...

Page 734: ...erential case assembly too tightly 4 Insert a 0 03 mm 0012 in feeler gauge at two places diagonally between differential case B and the thrust washer right Caution Do not insert a feeler gauge in the...

Page 735: ...left from the eleven types in the kit i Differential side Differential INSPECTION 1 Check the gears and differential pinion shaft for unusual wear or damage 2 Check the spline part of the differentia...

Page 736: ...surface with the viscous unit 2 Contact surface with the pinion mate washer 3 and 4 Contact surfaces with thrust washer ZllFOO35 Contact surface with differential 5 Check the spline part of the visco...

Page 737: ...e Inflation Pressure Check 4 Bald Spots Tire Wear Check 4 Cracked Treads Wheel Runout Check 4 Feathered Edge SPECIFICATIONS Rapid Wear at Center 2 General Specifications I 2 Rapid Wear at Shoulders Se...

Page 738: ...17 x 4 r 17 x 4T 2 Amount of wheel 14 55 14 55 14 III 1 o 55 zk 04 offset mm in 14 1 o 55 04 2 Pitch circle diameter 114 3 4 50 114 3 4 50 114 3 4 50 P C D mm in Spare tire Size T125 90D16 T125 90016...

Page 739: ...k of rotation llXO110 11x0117 Cracked treads Under inflation Adjust the tire pressure Wear on one side Excessive camber Inspect the camber Feathered edge Incorrect t o e i n Adjust the toe in Bald spo...

Page 740: ...th is less than the limit replace the tire NOTE When the tread depth of tire is reduced to 1 6 mm 06 in or less wear indicator will appear WHEEL RUNOUT CHECK Jack up the vehicle so that the wheels are...

Page 741: ...RS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review thi...

Page 742: ...41 Crossmember Bushing A projection mm in 7 2 10 2 28 40 Bushing B projection mm in 6 5 9 5 26 37 SPECIAL TOOLS Tool TROUBLESHOOTING Symptom Excessive engine Probable cause Cracked rubber parts of ins...

Page 743: ...h31 1 c 4A 35 Nm R 25 ft lbs i I Removal steps 1 Air hose G connection Turbo 2 Cruise control pump and link assembly Vehicles with Cruise Control 3 Engine mount bracket and body connection bolt 4 Eng...

Page 744: ...VICE POINT A4 MOUNTING STOPPER INSTALLATION Attach the engine mounting bracket so that the arrow mark on the mounting stopper is in the direction as shown in the d illustration INSPECTION l Check each...

Page 745: ...installation bolt 4 Transaxle mount bracket A 5 Mounting stopper Transaxle mount bracket E n g i n e Arrow mark INSTALLATION SERVICE POINT A MOUNTING STOPPER INSTALLATION Attach the transaxle mountin...

Page 746: ...1 2 43 Front roil stopper bracket and engine connection bolt Front roll stopper bracket installation bolt Front roll stopper bracket Heat protector Turbo ZOlFOO30 Rear roll stopper bracket removal ste...

Page 747: ...LATION Install the rear roll stopper bracket as shown in the illustration B REAR ROLL STOPPER BRACKET AND ENGINE CONNECTION BOLT INSTALLATION Install the bolt as shown in the illustration INSPECTION l...

Page 748: ...Power steering Fluid Air Bleeding Refer to GROUP 37A Service Adjustment Procedures l Front Wheel Alignment Adjustment Refer to GROUP 33A Service Adjustment Procedures l Transfer Oil Supplying AWD Ref...

Page 749: ...Stabilizer l Steering gear box Refer to GROUP 37A Power Steering Gear Box 13 Self locking nut 14 Clamp installal ion bolt short 15 Clamp installal ion bolt long 16 Clamp 17 Lower arm mounting bolt 18...

Page 750: ...rows on their bottom surfaces may be directed in the crosswise direction except those on No 1 crossmember of FWD vehicles Caution Shifting of the arrow in the direction of rotation shall be within 5 o...

Page 751: ...N S I O N CONTENTS FRONT SUSPENSION 33A ELECTRONIC CONTROL SUSPENSION ECS 33B ELECTRONIC CONTROL SUSPENSION ACTIVE PREVIEW ECS 33C NOTE i 1 Shaded groups in the above list are not included in this man...

Page 752: ...33 2 NOTES...

Page 753: ...ENTS LOWER ARM 10 SPECIFICATIONS s 2 ON VEHICLE SERVICE 6 General SpecificationS 2 Front Wheel Alignment 6 Service Specifications 3 Wheel Bearing Adjustment 6 STABILIZER BAR 12 SPECIAL TOOLS 4 STRUT A...

Page 754: ...I Orange x 1 Blue x 1 A T Orange x 2 Spring constant N mm Ibs in 30 168 From 1994 models Items Wire dia x O D x free length mm in Coil spring identification color FWD MTT 14 4 x 170 x 322 7 56x 6 69 x...

Page 755: ...out ECS Vehicles with ECS up to 1995 models I 150 5 91 1 080 238 Hard 2 530 558 Medium 1 580 348 Soft 620 137 Hard 1 190 262 Medium 1 120 247 Soft 970 214 Items Camber Caster Toe in mm in Standard val...

Page 756: ...Tools SPECIAL TOOLS Tool A MB991 237 B MB991 238 Compression of the front coil spring MB990326 General service P r e l o a d s o c k e t too Measurement of the ball joint and stabilizer link ball join...

Page 757: ...ring Wheel alignment Unbalanced or worn tires Broken or deteriorated stabilizer Shock absorber malfunction Improper tire inflation pressure Broken or deteriorated coil spring Shock absorber malfunctio...

Page 758: ...ner wheel 33 45 Outer wheel 28 21 CAMBER AND CASTER Standard value Camber 0 f 30 Caster 3 55 30 Install the special tool by tightening it to the same torque as that applied to the drive shaft nut To a...

Page 759: ...P 33A 6 i Removal steps 1 Brake hose tube clamp mounting bolt 2 Brake hose tube clamp 3 Front speed sensor clamp mounting nut ABS 4 Front speed sensor clamp ABS 5 Strut lower mounting bolt 6 Strut upp...

Page 760: ...does not adhere to the insulator s rubber part DISASSEMBLY SERVICE POINT A SELF LOCKING NUT REMOVAL 1 Holding the spring upper seat with the special tool loosen the self locking nut Caution The self...

Page 761: ...s easily accomplished with a pipe Q 8 mm x 300 mm 3 in x 11 8 in B SELF LOCKING NUT INSTALLATION 1 With the coil spring held compressed by the special tools MB991 237 and MB991 238 provisionally tight...

Page 762: ...izer link 4 Self locking nut connecting lower arm ball joint to knuckle 5 Lower arm mounting nut 6 Lower arm mounting bolt 7 Clamp mounting self locking nut 8 Clamp mounting bolt small 9 Clamp mountin...

Page 763: ...e tilts 6 1 with respect to the bottom surface of the lower arm then mount the self locking nut INSPECTION l Check the bushing for wear and deterioration l Check the lower arm for bend or breakage l C...

Page 764: ...cles with automatic transaxle 2 Transfer AWD Refer to GROUP 22 Transfer 6 40 Nm 29 ft lbs 1210011 0 0 0 0 0 6 2 7 3 Stabilizer link 4 Stabilizer bar bracket mounting bolt A 5 Stabilizer bar bracket 6...

Page 765: ...RQUE Install the nut to each stud Then use the special tool to measure the ball joint breakaway torque Standard value 1 7 3 2 Nm 15 28 in lbs BALL JOINT DUST SHIELD REPLACEMENT 1 Remove the clip ring...

Page 766: ...NOTES...

Page 767: ...to personal injuryordeathtoservicepersonnel from inadvertentfiringoftheairbag ortothedriverandpassenger from rendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related...

Page 768: ...color Green x 1 Green x 2 Brown x 1 Spring constant 29 162 29 38 N mm Ibs in 162 212 COIL SPRING Convertible Items Wire dia x O D x free length mm in Coil spring identification color Spring constant N...

Page 769: ...57 From 1994 models Items FWD AWD Wire dia x center dia x free length 11 6 x 105 x 350 0 mm in 46 x 4 13 x 13 78 11 5x105x379 3 45 x 4 13 x 14 93 Green x 1 Brown x 1 34 190 28 157 COIL SPRING Converti...

Page 770: ...Rear suspension FWD Rear suspension AWD Standard value Camber 0 30 0 t 30 0 10 30 Caster 3 55 ri 30 Toe in mm in Ozk3 Ok 12 At 2 5 02 1j 5 2 5 1 02f l SPECIAL TOOLS Tool ectronic control suspension l...

Page 771: ...r line is open circuited however it cannot be detected In a situation where anti roll control only stops if diagnostic trouble code No 21 is not on display a short circuited sensor output line 3 or op...

Page 772: ...terminal of G sensor and No 61 terminal of ECS control unit Correct harness Yes Is trouble cleared by replaced G sensor Yes 1 End Replace ECS control unit When diagnostic trouble code No 21 is output...

Page 773: ...e speed sensor Sensor power supply and ground and ground Is continuity provided between No 3 terminal of vehicle speed sensor and No 53 terminal of ECS control unit Yes 1 No Check vehicle speed sensor...

Page 774: ...ltage force drive actuator by scan tool Is terminal voltage up to specification Standard 9 V during forced drive of actuator for approx 1 sec 0 V except during forced drive Yes P N o Is trouble correc...

Page 775: ...ulb I LBetween No 11 and 3 terminals J 1 Yes 1 Is continuity provided between No 2 terminal of combination meter and ground Ee Correct harness I Yes I 1 Istroubleclearedbyreplacing combinationmwL Repl...

Page 776: ...connector with ignition switch at ON Check throttle position sensor Refer to P 33B 19 Good Yes 1No Replace E control unit 7 Replace throttle position sensor f N o No 1 terminal voltage and continuity...

Page 777: ...ng force changeover actuator including posi tion detection switch 2 ON BOARD DIAGNOSTIC OUTPUT CHECK When using the scan tool multi use tester MUT Up to 1993 models or MUT II call models 1 Connect sca...

Page 778: ...the basis of the deflection of the pointer of the voltmeter 5 Based on the diagnostic trouble code repair the associated defective portion 6 Set the ignition switch to OFF 7 Disconnect the battery cab...

Page 779: ...j lJljljL EEiPlZZL R L damping force ha zrr actuator NOTE 1 Control stop warning indication and fixed damping force return to normal when the ignition switch is set to OFF When any of the problems mar...

Page 780: ...is regarded as a problem 61 64 Damping force changeover ac If no damping force changeover is made in a second afteractuatordrive tuator defective signal has been output position detection switch outp...

Page 781: ...stationary condition 5 1 Anti Roll Control Function Check 1 Raise the front wheels on a jack and have them supported by rigid racks 2 Place the steering wheel in straight ahead position 3 Select the T...

Page 782: ...mulated vehicle speed at 60 km h 37 mph and 90 km h 56 mph similarly operate the accelerator pedal and check that the scan tool indications change over Entered simulated vehicle speed Accelerator oper...

Page 783: ...HECK 6 1 Actuator Operating Sound Check 1 Set the ignition switch to ON 2 Bring your ear near the top of the shock absorber NOTE In the case of the rear shock absorbers remove the trim cover at the to...

Page 784: ...0 0 0 0 OFF 0 0 STEERING ANGULAR VELOCITY SENSOR To mount or remove the steering angular velocity sensor refer to GROUP 54 Column Switch Remove the Steering wheel and clock spring before mounting or r...

Page 785: ...DAMPING FORCE CHANGEOVER ACTUATOR To remove or mount the position detection switch and damping force changeover actuator refer to GROUP 33A Strut As sembly and GROUP 34 Shock Absorber Assembly Caution...

Page 786: ...33B 20 ECS ECS Control Unit ECS CONTROL UNIT REMOVAL AND INSTALLATION Z12FOO98 Removal steps 1 Cargo floor box R H 2 Lid 3 ECS control unit 1 TSB Revision...

Page 787: ...ILIZER BAR 38 TRAILING ARM 32 TROUBLESHOOTING 24 UPPER AND LOWER ARM 29 REAR SUSPENSION cFWD ON VEHICLE SERVICE 5 Rear Hub Rotary sliding Resistance Check 6 Rear Wheel Alignment Check 5 Wheel Bearing...

Page 788: ...sAn SHOCK ABSORBER Items Specification Multi link Vehicles without ECS Vehicles with ECS 12X95X350 12 2 105 350 47 x 3 74 x 13 78 48x 4 13 x 13 78 Pink x 1 Orange x 1 35 196 35 196 Vehicles without EC...

Page 789: ...mm in 8 5 9 5 33 37 1 Wheel bearing end play mm in 1 Rear hub rotary sliding resistance N Ibs 0 05 002 or less 31 7 or less SPECIAL TOOLS Tool TOOI number and Supersession name MB991113 MB991 113 01...

Page 790: ...Arm set MB991 045 Bushing remov er and installer MB990880 Arbor MB990847 Base Supersession MIT62220 MB991 005 01 MB991389 01 Application Compression of the coil spring Removal and installation of the...

Page 791: ...r One graduation changes camber by about 15 TOE IN Standard value 0 5 2 5 mm Ol 09 in To adjust toe turn the assist link mounting bolts on crossmem ber side on both sides the same amount NOTE 1 The di...

Page 792: ...place the rear hub bearing unit if an adjustment cannot be made to within the limit REAR HUB ROTARY SLIDING RESISTANCE CHECK 1 inspect the play of the bearings while the vehicle is jacked up and resti...

Page 793: ...ehicle Service l Absorber Lid to Rear Side Trim Installation Refer to GROUP 52A Trims Z12FOllO Removal steps 1 Shock absorber mounting nuts upper 2 ECS connector EC 3 Cap 4 Brake tube clannp bolt 5 Br...

Page 794: ...unting nut and rear suspension assembly INSPECTION l Check the crossmember for cracks or deformation l Check the bushings for cracks or deterioration CROSSMEMBER BUSHING REPLACEMENT 1 Using the specia...

Page 795: ...nd nut Assist link removal steps 8 Assist link mounting bolt and nut 9 Self locking nut 10 Assist link 4 Upper arm Lower arm removal steps 5 Lower arm mounting bolt and nut 6 Self locking nut 7 Lower...

Page 796: ...over Snap ring 212R0119 Removal Pressure fitting l NOIOl J BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool measure the ball joint breakaway torque Standard value 2 9 Nm 17 78 in lbs BALL J...

Page 797: ...lt Rear brake disc Hub cap Wheel bearing nut Rear hub assembly Parking brake cable clamp bolt bAd 13 4Bb 2 16 17 Parking brake cable end Refer to GROUP 36 Parking Brake Rear speed sensor clamp bolt CA...

Page 798: ...kle from the lower arm upper arm and assist link Caution 1 Be sure to tie the cord of the special tool to a nearby part 2 Loosen the nut but do not remove it wrench 212AOlOO Press fit I I Removal INST...

Page 799: ...orber upper mounting nut 3 l clc nnnnnrtnr CCC L L IIIIU L I L n n J biqJ 4 Brake tube clamp bolt 5 Shock absorber lower mounting bolt 6 Shock absorber NOTE I Indicates parts which should be temporari...

Page 800: ...acket assembly 5 Upper spring pad 6 Upper bushing B Z12A0328 7 Collar 8 Cup assembly 9 Dust cover 10 Bump rubber A 11 Coil spring 12 Shock absorber DISASSEMBLY SERVICE POINT A PlSTON ROD TIGHTENING NU...

Page 801: ...he shock absorber spring seat as shown FBdBRACKET ASSEMBLY t PISTON ROD TIGHTENING NUT INSTALLATION 1 With the position of the bracket assembly as shown in the figure tighten the tightening nut to the...

Page 802: ...locking nut A 9 Stabilizer link 10 Joint cup A 11 Stabilizer rubber 12 Stabilizer bar INSTALLATION SERVICE POINTS AdSTABlLlZER LINK SELF LOCKING NUT SELF LOCKING NUT INSTALLATION 1 Hold the stabilize...

Page 803: ...r wear and deterioration l Check the stabilizer bar for deterioration or damage l Check the stabilizer link ball joint dust cover for cracks l Check all bolts for condition and straightness STABILIZER...

Page 804: ...8 Rear rotor CABS 9 Rear hub unit bearing Caution Rear hub unit bearing cannot be disassembled REMOVAL SERVICE POINTS dA REAR SPEED SENSOR REMOVAL ABS Caution Be careful when handling the pole piece...

Page 805: ...al lip is pushed in the reverse direction resulting in oil leaks or loose mounting D REAR ROTOR REMOVAL CABS Caution Care must be taken not to scratch or scar the rotor s toothed surface and not to dr...

Page 806: ...3 45x4 13x14 93 I I Coil spring identification color 1Light brown x 2 Spring constant N mm IbeAn cl 996 models Items 28 0 157 Specifications Wire dia x O D x free length mm in Coil spring identificati...

Page 807: ...ylindrical double acting type 610 24 0 Min length mm in 407 16 0 Stroke mm in Damping force at 0 3 m set 0 9 ft set N Ibs Expansion 203 8 0 1 400 309 I Contraction 500 110 SERVICE SPECIFICATIONS Items...

Page 808: ...MB991113 MB991113 01 Disconnection of the ball joint Steering linkage puller Em MB990326 General service Measurement of the ball joint break away tool torque 0 J Preload socket 8 0 MB990800 Ball joint...

Page 809: ...REAR SUSPENSION AWD Special Tools 34 23 B lMB990244 i TSB Revision...

Page 810: ...34 24 REAR SUSPENSION AWD Troubleshooting TROUBLESHOOTING TSB Revision...

Page 811: ...e turn the trailing arm mounting bolts on the crossmember side on both sides the same amount NOTE Left wheel Clockwise toe out Right wheel Clockwise toe in The difference between right and left wheels...

Page 812: ...36 On vehicle Service 50 60 Nm 4 _ 12 36 43 ft lbs 5 30 35 Nm Bi 1 45 Nm 3 3 ft lbs 2 80 94 ft lbs bx Ibs 6 Removal steps 1 Shock absorber mounting nuts bweO 2 ECS connector cECS 3 Cap 4 Brake tube t...

Page 813: ...jack requires three persons as the rear suspension assembly is very heavy Assign one person to the differential and one each to the left and right lower arm 3 Apply a wood block to the ball joint of...

Page 814: ...e Dimension A 15 5 mm 59 in Dimension B 2 1 3 7 mm 08 15 in CROSSMEMBER BUSHING REAR REPLACEMENT 1 Using the special tool remove and press fit the bushing 2 When press fitting position the bushing as...

Page 815: ...12FOO93 00001036 Nm ft lbs Lower arm removal steps 5 Lower arm mounting nut 6 Lower arm mounting bolt A4 7 fzbilizer link to lower arm coupling 4Bb 8 Self locking nut 9 Lower arm NOTE Indicates parts...

Page 816: ...the self locking nut so that the protrusion of the stabilizer link dimension A indicated in illustration is within the standard value Standard value A 5 7 mm 197 276 in INSPECTION l Check the bushing...

Page 817: ...B991 073 YlZNOlOl Press fit Pipe lower am OLer pipe bushing 12A003 LQWER ARM BUSHING REPLACEMENT 1 Use the special tool to remove and press fit the bushing 2 Press fit the lower arm bushing until the...

Page 818: ...to companion flange mounting bolt and nut 4 Self locking nut 5 Companion flange 6 Rear axle shaft 7 Parking brake cable end 8 Parking brake cable clamp bolt 9 Rear speed sensor CABS 10 Rear speed sen...

Page 819: ...he ball joint from the knuckle Caution 1 Be sure to tie the cord of the special tool to a nearby part 2 Loosen the nut but do not remove it Press fit Removal Trailina arm bushina 2i2A0298 INSPECTION l...

Page 820: ...rked C in the illustration to remove the connecting rod 5 Installation of the body special tool should be performed with the screw shaft and guide shaft center lines oriented as shown in the illustrat...

Page 821: ...lbs 58 Nm A12F0126 A 1 Assist link NOTE L H side shown Bolt Lock nut A12FO125 42 ft lbs INSTALLATION SERVICE POINT A ASSIST LINK INSTALLATION If the ball studs of the assist link does not align with...

Page 822: ...LATION Pre removal and Post installation Operation 0 Rear Side Trim Absorber Lid Removal and Installation Refer to GROUP 52A Trims Removal steps 1 Shock absorber upper mounting nut 2 ECS connector EC...

Page 823: ...tightening nut Refer to P 34 14 i 3 Washer 4 Upper bushing A 5 Bracket assembly Refer to P 34 15 6 Spring pad bushing B 9 Cup assembly 10 Dust cover 11 Bump rubber 12 Coil spring Refer to P 34 15 13 S...

Page 824: ...Ibs 11 4WS piping fixing bolt 4WS 12 Rear shock absorber mounting bolt 13 Power cylinder mounting bolt 4WS 14 Crossmember bracket t 15 Crossmember mounting nut 16 Stabilizer bracket 4Bb 17 Bushing 18...

Page 825: ...B STABILIZER BAR REMOVAL 1 Lower the transmission jack a little to obtain a gap between the rear suspension and body 2 Remove the stabilizer bar INSTALLATION SERVICE POINTS A STABlLlZER LINK SELF LOC...

Page 826: ...E CHECKING Using the special tool measure the ball joint breakaway torque Standard value 1 7 3 2 Nm 15 28 in lbs BALL JOINT DUST COVER REPLACEMENT 1 Remove the clip ring and the dust cover 2 Apply mul...

Page 827: ...and Adjustment 63 Service Specifications 3 Check Valve Operation Check 65 TROUBLESHOOTING 5 Front Brake Disc Run out Check 70 WHEEL SPEED SENSOR ABS 113 I Front Brake Disc Run out Correction 70 WARNIN...

Page 828: ...Brake pedal depressing force PROPORTIONING VALVE Items Convertible Hatchback Split point MPa psi 4 95 5 45 704 775 3 75 4 25 533 604 Decompression ratio 0 43 0 96 FRONT BRAKES REAR BRAKES Items FWD AW...

Page 829: ...ngenti mounting bolts N Ibs Speed sensor s internal resistance CABS kQ Solenoid valve HU resistance R Up to 1995 models Hydraulic unit solenoid valve inte nal resistance R G sensor output voltage V cl...

Page 830: ...e of inner shim A inner shim Brake grease SAE J310 NLGI No 1 B and outer shim Guide pin and lock pin sliding part Piston boot inner surface Pin boot inner surface Repair kit grease SEALANTS Items Spec...

Page 831: ...uate contact of pad Correct Auto ad juster malfunction Adjust Insufficient braking Low or deteriorated brake fluid Add or refill Dower Air in brake system Bleed air from system Overheated brake rotor...

Page 832: ...otina Insufficient parking brake function Excessive parking brake lever stroke the parking brake lever stroke ck the parking brake cable rout Scraping or grinding noise when brakes are applied when br...

Page 833: ...m is functioning nor mally 2 When the vehicle speed reaches approximately 6 km h 4 mph after the engine is started and the vehicle starts off for the first time a whining motor noise may be heard from...

Page 834: ...S warning light remains lit because the valve position the ABS ECU causes the ABS warn relay is OFF ing light to flash twice in about one second 3 When the ignition key is returned from the during whi...

Page 835: ...or malfunction of ABS op CONTINUED ON NEXT PAGE eration i Yes T r o u b l e c o n d i t i o n Major causes One sided braking lnsuff icient braking force l Hydraulic line in HU is clogged l Mechanical...

Page 836: ...l No layout for troubleshooting Terminal No layout shown on the special tool connector 00002535 If trouble does not reappear 1 watch vehicle movements until it reappears Refer to P 35 11 Caution 1 Whe...

Page 837: ...cleared LJ Actuator test specifications I I No Scan tool display Drive solenoid Drive pattern valve and motor The actuator can be forcibly driven in the following way by using the scan tool NOTE l The...

Page 838: ...the light Hint If other warning lights do not light up either fuse is probably blown IGNITION SWITCH IG2 IGNIT SWITC 3N Gl 127 KXI kKK R35Rl I1 2 f I w A k s 00 3 d 2 ____ ________ J B 0 I IN5g ABS P...

Page 839: ...BS warning light normal for burned bulb Remove the combination me ter and check with the igni tion key ON i Does voltage between har ness connector terminal No 14 and ground indicate bat tery positive...

Page 840: ...nstall the valve relay remove the HU connector and check K i E3 4 Repair harness Does positive voltage between the HU harness connector termrnal No 8 and ground rndrcate battery positive voltage while...

Page 841: ...l safe mode In such a case erase the diagnostic trouble code and then restart the engine to check if the system is currently in a fault condition EYWP E b IGNiTlOW SWITCti IG1 86 87 I t I 30 1 85 87a...

Page 842: ...cate with scan tool function Repair and re check Yes Correct cause of blown Disconnect ECU connector and check harness connector Is there continuity between body harness terminals No 9 and No 34 and g...

Page 843: ...ntrol No Scan tool related mal systems communicate with scan tool function Repair and re check Correct cause of blown fuse and replace fuse Disconnect ECU connector and check harness connector No Yes...

Page 844: ...ow er to the ABS ECU Discon nect the hydraulic unit connec tor A 64 and the ABS valve relay connector A 65 In spect the harness side of both connectors for damage to the terminal pins Repair terminal...

Page 845: ...s only when the valve relay is off in the valve relay test etc IGNITION SWITCH lG1 T j w J B ABS ECU Disconnect the hydraulic unit connector A 64 and the ABS ECU connector E 12 Inspect the harness sid...

Page 846: ...e scan tool mode ABS does not function If it does not go into the scan tool mode check the ECU power circuit and the harness between the ECU and diagnostic output terminals 2 Read the on board diagnos...

Page 847: ...ty l Distortion of rotor teeth missing l Low frequency noise interference when sensor harness wire is broken l Noise interference in sensor signal l Sensor output signal is below the standard val ue o...

Page 848: ...lue Front 0 3 0 9 mm 012 035 in Rear 0 2 0 7 mm 008 028 in Adjust the gap between the Yes t Is the wheel speed sensor ro No Replace rotor that has mis tor normal with no missing or sing or damaged tee...

Page 849: ...tch may remain on for more than is a malfunction in the ABS ECU 15 minutes without ABS operation l The harness wire for the stop light switch may be open Do the stop lights light up and go out normall...

Page 850: ...and then these diagnostic trouble codes are output IGR ITION SWiTCy IG1 G R l G R SOLENOID I I ABS ECU Ll 121 3 14 15 1617 6 19 jlO l1 12 13 i4 15 16 17 16 19 20 1e2 23 426i26 7 6 30 1 2l 5 Iu 35 AK R...

Page 851: ...7a III81 __ _ 1 I p iiazq __________________ 1 T P B 1 1227 I ABS 22 ECU P 1 i SE L L IGNITION SWITOH IG1 Remove and check the valve relay t When the valve relay is checked are the following conditio...

Page 852: ...motor ground line is disconnected and the motor does not revolve FUGIBLE LINK I Does the motor make a noise Yes during scan tool forced drive mode No Remove the motor relay i I No Remove the motor re...

Page 853: ...ng which the valve relay self check is made again and then goes out 214AO594 0 0 0 0 2 1 6 5 7 No Trouble condition Major causes Remedy 1 ABS warning light does not light up at all l ABS warning light...

Page 854: ...ficient CONTINUED ON NEXT PAGE braking force or malfunction of ABS op eration Yes Trouble condition Major causes One sided braking lnsuff icient braking force Decline in ABS function ABS sometimes fun...

Page 855: ...minals and the diagnosis check connector Referring to the diagnostic trouble code check chart E l E 7 make the diagnostic trouble code reoccur to discov er the main cause of intermit tent or other tro...

Page 856: ...ions ACTUATOR TEST FUNCTION The actuator can be forcibly driven in the following way by using the scan tool NOTE l The actuator test cannot be carried out when the ABS ECU system is in fail safe mode...

Page 857: ...not light up either fuse is probably blown IGNITION SWITCH IG2 IGNI SWITi N IGl TIO 3 m d t r i 2 _ __ ____ J B 0 G 1234 BE 5678 3 3 7 i i 6 2 5 I I c R i Efi RELAY RELAY E KoEgg4 B E5LS c 6 2 5 0 G...

Page 858: ...er t Turn the ignition switch OFF and check No c ABS warning light bulb Replace ABS warning light Check for burned bulb burned bulb i Yes Is there continuity between combination meter No 58 and No 59...

Page 859: ...efer to P 3583 I 1 Valve relay malfunction Replace valve relay I 1Yes Install the valve relay remove the HU con 1 No Does voltage between the HU harness connector terminal No 8 and ground indi w 1 Bro...

Page 860: ...l If the diagnostic trouble code is output the system can be in the fail safe mode In such a case erase the diagnostic trouble code and then restart the engine to check if the system is currently in a...

Page 861: ...3565 I Yes No Power relay malfunction I Replace power relay Disconnect ECU connector and check harness connector 1 With the ignition key in the ON position does voltage be tween ECU connector terminal...

Page 862: ...er electronic control systems communicate with scan tool tion Repair and recheck Disconnect ECU connector and check harness connector Is there continuity between body harness terminals No 9 and No 34...

Page 863: ...rcuit on the valve relay side sequently in the START position power is off L FUS LIN IGNIT IN swm 1Gl G R 11 G R I L SmJ 12 8 1I L1 17 7 u 1 I 30 ii ______ _______ ABS ECU KK35 AK R3513 N Remove the N...

Page 864: ...is a break in the harness between the ECU and the warning light the light illuminates only when the valve relay is off in the valve relay test etc IGNITION SWITCH IG1 I J B fX NAT ON A 3 ECU I25 Disco...

Page 865: ...he scan tool mode In the scan tool mode ABS does not function If it does not go into the scan tool mode check the ECU power circuit and the harness between the ECU and diagnostic output terminals 2 Re...

Page 866: ...ormality l Distortion of rotor teeth missing l Low frequency noise interference when sensor harness wire is broken l Noise interference in sensor signal l Sensor output signal is below the standard va...

Page 867: ...cuit is broken Repair harness L 214NOlW i Is the front wheel speed sen sor to rotor clearance nor mal Standard value Owl 0 3 0 9 mm 012 035 in Yes I Yes Is the rear speed sensor mounting surface to ro...

Page 868: ...sensor OFF trouble It is judged that the G sensor continues to be OFF for more than approximately 13 seconds except when the l When there is a broken wire or short circuit in the harness for the G se...

Page 869: ...h remains on for more than 15 is a malfunction in the ABS ECU minutes while the ABS is not functioning l The harness wire for the stop light switch may be open cup to 1994 models F SiSLE LINKQ 1995 mo...

Page 870: ...CU con 1 When the brake pedal is No py I Repair harness 1 Zjrr o ZtKYZ pjii zq bl Repair harness I I Yes Is resistor resistance 780 to 860 a Replace resistor IYes Is there continuity 2 terminal and gr...

Page 871: ...d if the current value of the solenoid valves differs from each other in the same mode solenoid valve drift error is produced and the ABS ECU goes into the failsafe mode iLJ c iGNiTlON SWITCH IG1 m 59...

Page 872: ...uble code will be output is normal In addition normally it monitors whether IGNITION SWITCH IGil Remove and check the valve relay No 30 No 87a Continuity No 30 No 87 No continuity When battery voltage...

Page 873: ...r make a noise during scan tool forced drive mode No Remove the motor relay I Remove the motor relav and check resistance values No 85 No 86 Resistance value 72 88 SLZ No 30 No 87 No continuity Batter...

Page 874: ...can sometimes be heard coming from inside the engine compartment but this is because the system operation check is being performed This is considered normal 1 2 Sound of the motor inside the ABS hydr...

Page 875: ...ecial tool diagnostic trouble code check harness to ground the terminal 1 of the data link connector 2 Take a reading of the diagnostic trouble code from the flashing of the ABS warning light Diagnost...

Page 876: ...succession according to the timing given below Caution The memory cannot be erased under the following conditions 1 When the stop light switch is not turned on and off according to the table below 2 W...

Page 877: ...shorted 23 R R wheel speed sensor system shorted 24 R L wheel speed sensor system shorted 26 G sensor system open or short circuited or signal provided abnormally 38 Stop light switch system open cir...

Page 878: ...sensor and ABS ECU t Check wheel speed sensor output voltage Check wheel speed sensor IOK Replace wheel speed sensor y Repair 1 C h e c k r o t o r loK ILeI Check the following connector Replace roto...

Page 879: ...ssary l Start engine Measure voltage between terminal No 83 and body ground OK Batterv voltaae Check harness between ignition Repair Check battery lnu Code Nos 21 22 23 and 24 Wheel speed sensor syste...

Page 880: ...nsor and ABS ECU and repair if necessarv NG Check the following Repair 1OK r Check trouble symptoms Replace ABS ECU Code No 38 Stop light switch system open circuited or ON trouble Probab e cauSe Outp...

Page 881: ...ABS ECU defective or short circuited or harness is judged to be broken or shorted and output is provided Check solenoid valve Refer to P 35 112 IOK Replace HU t vleasure at HU connector A 64 and jBS E...

Page 882: ...12 l Disconnect connectors and make measurements on har ness side l Resistance between 82 47 c 94 A 80 1OK Repair NG L Check solenoid valve Refer to P 35 112 AOK Replace HU Check harness between ABS v...

Page 883: ...est Check harness between HU and ABS ECU and Is sound of HU pump motor running is heard Check ABS motor relay Refer to i 35 83 Check harness between main fusible link No and ABS motor relay and repair...

Page 884: ...ent the wheels from locking There is nothing abnormal INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 No communication is possible between scan tool and any cbable cauSe of control sy...

Page 885: ...ECU Data link side connector side 68 1 38 7 OK lG I Check the followina connector 1 NG Repair WNG Confirm trouble symptoms i Check harness between ABS ECU 1Check the f 1 NG Repair Measure at ABS ECU c...

Page 886: ...air if Inspection procedure 4 Check that bulb has not burned out Replace ABS warning light bulb OK NG Repair D l 6 D 04 D 44 C 71 C 82 OK Check trouble symptoms Replace combination meter ABS warning l...

Page 887: ...osited on it Check wheel speed sensor NG Repair installation Check HU Refer to P 35 76 l Wheel bearing defective l HU defective l ABS ECU defective Check wheel speed sensor 1OK Replace wheel speed sen...

Page 888: ...CHART The following actuators can be force driven by use of the scan tool NOTE 1 Actuator test cannot be made when ABS ECU is not functioning 2 Actuator test can be carried out only when the vehicle...

Page 889: ...turn and secure by tightening the lock nut 4 Connect the connector of the stop light switch 5 Check to be sure that the stop light is not illuminated with the brake pedal released Reference value B O...

Page 890: ...re is continuity when the float surface is below A BRAKE BOOSTER OPERATING CHECK For simple checking of brake booster operation carry out the following tests 1 Run the engine for one or two minutes an...

Page 891: ...eplace it as an assem bly unit together with the vacuum hose PROPORTIONING VALVE FUNCTION TEST 1 Connect two pressure gauges one each to the input side and output side of the proportioning valve as sh...

Page 892: ...w worker plug the master cylinder outlet with finger 4 Keeping the condition 3 release the brake pedal 5 Repeat steps 2 to 4 three to four times while filling the master cylinder with brake fluid BLEE...

Page 893: ...ed with special grease Do not wipe off the special grease on the lock pin and do not contaminate the lock pin 3 Remove the following parts from the caliper support 1 Pad and wear indicator assembly 2...

Page 894: ...heck for dirty or corroded piston sliding surface and deteriorated piston seal cAWD 1 Visually check the brake pad thickness Through the open ing in the caliper body Standard value 10 0 mm 39 in Limit...

Page 895: ...I No 1 Caution 1 Make sure that the friction surfaces of pads and brake discs are free of grease and other contami nants 2 The grease should never squeeze out from around the shim 7 Start the engine d...

Page 896: ...rake lathe MAD DLl 8700PF or equivalent Be sure to follow the exact brake lathe manufacturer instructions FRONT BRAKE DISC RUN OUT CHECK 1 Remove the front brake assembly and support it with a wire et...

Page 897: ...often have a lower run out than a new brake disc REAR DISC BRAKE PAD CHECK AND REPLACEMENT 1 Check brake pad thickness through caliper body check port Standard value 10 0 mm 39 in Limit 2 0 mm 08 in C...

Page 898: ...he pad clip to the caliper support Caution Do not deposit grease or other dirt on pad or brake disc friction surfaces 7 Clean the piston and then using the special tool push the piston into the cylind...

Page 899: ...port it by a wire etc 2 Place a dial gauge approximately 5 mm 2 in from the outer circumference of the brake disc and measure the run out of the disc Limit 0 08 mm 0031 in or less NOTE Tighten nuts to...

Page 900: ...any location of the brake lining thickness is less than the limit Caution Whenever the shoe and lining assembly is replaced replace both RH and LH assemblies as a set to prevent car from pulling to o...

Page 901: ...No same for AWD and FWD 3 Manually turning the wheel to be measured by l 2 to 1 turn second measure the output voltage with a circuit tester or oscilloscope Output voltage When measured with circuit...

Page 902: ...odels or MUT II All models 1 Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack up points 2 Release the parking brake and determine the drag force drag torque of...

Page 903: ...ation Normal Abnormal condition condition Probable cause Remedy 04 FR VALVE M 1 Depress brake pedal Brake force Wheel does Clogged Check and to lock wheel released for 6 not lock when brake line clean...

Page 904: ...nition switch beforehand whenever the scan tool is connected or disconnected 3 After confirming that the shift lever or selector lever is in the neutral position start the engine The ABS warning light...

Page 905: ...normal Probable condition cause Brake force in Step 1 shows very little or almost no decrease Brake force de creases in Step 1 but in Step 2 it shows very little or almost no in crease Increasing brak...

Page 906: ...the ignition key to the OFF position and set the scan tool as shown in the diagram 4 After checking that the shift lever M T or the selector lever A T is in neutral start the engine NOTE 1 At this tim...

Page 907: ...e Wheel does Clogged Check and M lock wheel released for not lock brake line clean brake 2 Using the scan tool 2 seconds when brake otherthan HU line FL VALVE select the wheel to be after locking peda...

Page 908: ...misfiring and fail to start if an attempt is made to start without allowing the batterty to recover sufficientry This is because the ABS consumes a great deal of current for its self check In such a...

Page 909: ...ized and de energized Motor Relay When de energized Between terminals 30 60 A 85 and 86 Between terminals No continuity 30 and 87 Q When energized be Between terminals Continuity Ede 8 rminals 85 30 a...

Page 910: ...Brake Pedal Adjustment Refer to P 35 63 FWD MTT 14 14 w 214A0256 21 30 Nm 22 ft lbs i m 6 214FO106 20 0 0 0 0 2 1 2 9 Stop light switch removal steps 1 Stop light switch connector 2 Stop light switch...

Page 911: ...rn spring 4 Cotter pin 5 Washer 6 Clevis pin 7 Cotter pin 8 Shift lock cable connection 9 Brake pedal assembly parts from step 10 to step 21 10 Brake pedal shaft bolt 11 Lever assembly installation nu...

Page 912: ...g for wear l Check the brake pedal for bend or twisting l Check the brake pedal return spring for damage STOP LIGHT SWITCH CHECK 1 Connect a circuit tester to the stop light switch 2 The stop light sw...

Page 913: ...02132 Master cylinder removal steps 1 Low pressure hose 2 Brake fluid level sensor connector 3 Brake tube connection 4 Master cylinder Brake booster removal steps B l Clearance between brake booster p...

Page 914: ...he brake booster nipple as shown in the figure Secure the hose with the hose clip Caution The check valve and the pipe part of the brake booster must not contact each other 2 Install the other end of...

Page 915: ...ter 0 55 0 75 mm 022 030 in 8 9 inch brake booster 0 65 0 85 mm 026 033 in If the clearance is not within the standard value range turn the push rod screw to achieve desired length Caution Improper cl...

Page 916: ...epressing the piston C SECONDARY PISTON ASSEMBLY DISASSEMBLY NOTE If it is hard to remove the secondary piston from the cylinder gradually apply compressed air from the outlet port on the secondary en...

Page 917: ...leeding Refer to P 35 66 1 Brake hose 2 Brake tube strut 3 Brake tube A 4 Brake tube B 5 Brake tube front R H 6 Brake tube front L H 7 Brake tube main R H 8 Brake tube main L H 14 Proportioning valve...

Page 918: ...of hydraulic unit Up to 1995 models From 1996 models m 5 4 12 11 3 6 14FOOlQ 4 5 12 11 1480167 14FOllO 00003717 1 Brake hose 2 Brake tube strut 8 Brake tube main L H 3 Brake tube A 9 Brake tube cup t...

Page 919: ...for right front and left rear From 1996 models 1 HU front brake L H 2 HU rear brake R H 3 H U rear brake L H 4 HU front brake R H 5 Master cylinder HU for left front and right rear 6 Master cylinder...

Page 920: ...tool and then install the caliper body 3 Start the engine depress the brake pedal firmly two to three times and stop the engine 4 Turn the brake disc ten times in the forward direction 5 Using a spri...

Page 921: ...pl 1 Guide pin Pad assembly disassembly steps A 1 Guide pin A4 2 Lo pin A 2 LOCK pin 3 Busnlng 3 Bushing 4 Caliper support pad clip shim 4 Caliper support pad clip shim 11 Pad wear indicator 5 Pin bo...

Page 922: ...ont Disc Brake Lubrication points 214K069 Zl4Yl84 Brake fluid Conforming to DOT3 or DOT4 Grease Repair kit grease orange r Z14AO54 I Grease Repair kit grease orange I Z14L0128 1 Grease Repair kit grea...

Page 923: ...one cannot be removed dB PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not damage the cylinder inner surface 2 Clean piston surface and inner cylinder with trichloroethy lene al...

Page 924: ...s less than the i limit value d Standard value 10 0 mm 39 in Limit value 2 0 mm 08 in 14WOD95 Caution 1 When the limit is exceeded the brake pads on both the left and right wheels must be replaced as...

Page 925: ...I Seal and boot kit l2 10 g 43 10 0 4 0 d Q Q S r eaY b I 214FO120 Brake caliper kit Z14FO118 Disassembly steps 1 Clip 2 Pad pin 3 Cross spring 2 ma mbly 8 Outer pad 9 Retaining ring 10 Piston boot 1...

Page 926: ...tion ZUY184 The piston seal contained in the seal and boot kit is coated with special grease lo not wipe off the grease Brake fluid Conforming to DOT3 or DOT4 214FOO24 1 Grease _ Zl4FOO97 I Grease Bra...

Page 927: ...ut evenly Caution 1 Be careful not to get your fingers to be pinched 2 Be careful not to let the brake fluid splash D PISTON SEAL REMOVAL 1 Remove the piston seal Caution Do not damage the cylinder in...

Page 928: ...thickness is less than the limit value d Standard value 10 0 mm 39 in Limit 2 0 mm 08 in Caution 1 When the limit is exceeded the brake pads on both the left and right wheels must be replaced as a set...

Page 929: ...15 Nm AWD 50 60 Nm 36 43 ft lbs 11 ft lbs Z14N0036 0 0 0 0 2 1 4 6 i Removal steps 1 Brake hose A 2 Rear brake assembly 3 Brake disc INSTALLATION SERVICE POINT FAA REAR BRAKE ASSEMBLY INSTALLATION Ins...

Page 930: ...Grease Caliper assembly disassembly steps A 1 Lock pin FAA 2 Guide pin 3 Bushing 4 Caliper suppart Boot 4 7 shim 10 5 ring 12 Piston boot 13 Piston 14 Piston seal 15 Caliper body Pad assembly disasse...

Page 931: ...Seal and boot kit 9 2018 l7 11 Grease 214FO140 Z14FO120 Caliper assembly disassembly steps 9 Pad pin 11 Retaining ring 12 Piston boot 13 Piston 14 Piston seal 15 Caliper body Pad assembly disassembly...

Page 932: ...pad clip shim 7 Lock pin boot 8 Guide pin boot 10 Boot ring 12 Piston boot 13 14 Piston Piston seal 15 Caliper body A 00002147 Pad kit Seal and boot kit Z14N0156 4 8 Grease Z14N0157 Pad assembly disas...

Page 933: ...luid Conforming to DOT3 or DOT4 Y14N0121 Grease Repair kit grease orange AWD From 1994 model2 Caution The piston seal contained in the seal and boot kit is coated with special grease Do noi wipe off t...

Page 934: ...h your fingers 2 Be careful not to splash the brake fluid B PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not damage the cylinder inner surface 2 Clean piston surface and inner c...

Page 935: ...ad thickness is less than the limit value Standard value 10 0 mm 39 in Limit 2 0 mm 08 in Caution 1 When the limit is exceeded the brake pads on both the left and right wheels must be replaced as a se...

Page 936: ...2 Fender l Air Duct installation l Relay Box Installation l Brake Fluid Filling 0 Bake Line Bleeding Refer to P 3566 Flared brake line nuts 15 Nm 11 ft lbs 4FO3s Hydraulic unit removal steps A B 1 Bra...

Page 937: ...Caution 1 The HU is heavy Use care when removing it 2 The HU cannot be disassembled Never loosen its nuts or bolts 3 Do not drop or shock the HU 4 Do not turn the HU upside down or lay it on its side...

Page 938: ...N SOLENOID VALVE CHECK From 1996 models Measure resistance between terminals of each of the following solenoid valves Standard value L Front IN left side 2 1 2 8 5 9 5 Sz Front OUT left side 6 1 2 4 4...

Page 939: ...BS REMOVAL AND INSTALsLATION 4WD 9 ft lbs 5 i 1 Front rotor 2 Rear rotor Front speed sensor removal steps 214FOO78 Rear speed sensor removal steps 6 Clip 8 Rear speed sensor 3 Clip qB C 4 Front speed...

Page 940: ...teps 3 Clip AB C 4 Front speed sensor Rear speed sensor removal steps 6 Clip 7 Cable band B A 8 Rear speed sensor 9 O ring REMOVAL SERVICE POINTS dAbFRONT ROTOR REAR ROTOR REMOVAL Caution Do not damag...

Page 941: ...les In this case measure the sensor mounting surface to rotor tooth surface clearance Standard value 28 15 28 45 mm 1 11 1 12 in BA FRONT SPEED SENSOR BRACKET INSTALLATION NOTE 1 The right and left sp...

Page 942: ...ole piece is damaged accurate wheel speed detection may not be expected 2 Measure resistance between speed sensor terminals Standard value cFWD Front 0 8 1 2 kL Rear 0 6 0 8 k 2 AWD 0 8 1 2 kG If the...

Page 943: ...G sensor 3 G sensor bracket Z14AO194 Z14A0195 INSPECTION G SENSOR CHECK cup to 1995 models 1 Lay the G sensor on a level surface and check for continu ity between its terminals 2 Incline the G sensor...

Page 944: ...2 With the ignition switch turned ON read output voltage between terminals No 2 and No 3 Standard value 2 3 2 7 V 3 With the special tool connected fix the connector in such a manner as to direct the...

Page 945: ...ushion Installation l ABS Inspection Refer to P 357 14FOO79 From 1996 models 14FO169 00003719 Removal steps 1 Control unit connector connection 2 Electronic control unit 3 ABS ECU bracket REMOVAL SERV...

Page 946: ...NOTES...

Page 947: ...bag ortothedriverandpassenger fromrendering the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSU...

Page 948: ...type Lever type Cable arrangement V type SERVICE SPECIFICATIONS LUBRICANTS Items Specified lubricant Rear brake shoe and backing plate contact surfaces Brake grease SAE J310 NLGI No 1 Contact surface...

Page 949: ...e shaft assembly General service tool MB990211 01 General service tool Application Symptom Brake drag lnsuff icient parking brake function 1Probable cause 1 Remedy Incomplete release of parking brake...

Page 950: ...expand the shoe until brake is lightly applied where the disc cannot be turned with both hands approx 2 7 Nm 23 in lbs Then turn the adjuster five notches in the direction opposite the arrow Reference...

Page 951: ...rive the vehicle at a constant speed of 35 50 km h 22 31 mph for 100 m 328 ft 4 Release the parking brake and let the brakes cool for 5 10 minutes 5 Repeat the procedure in steps 2 to 4 4 5 times Caut...

Page 952: ...val steps 1 Cable adjuster 6 Rear speed sensor Refer to GROUP 35Speed Sensor 7 Rear brake assembly 8 Rear brake disc 9 Adjusting wheel spring 10 Shoe hold down cup 11 Shoe hold down pin Bd 12 Adjuster...

Page 953: ...TALLATION The shoe to anchor spring must be installed in the sequence shown in the illustration Caution Each shoe to anchor spring has a unique spring load and the spring a is painted to prevent erron...

Page 954: ...5 a Z14D0650 Grease Brake grease SAE 5310 NLGI No 1 Removal steps A E 1 Rear speed sensor 3 Rear brake assembly 4 Rear brake disc 5 Hub cap WI paw nut 8 Rear hub unit bearing 12 Adjusting wheel spring...

Page 955: ...e SAE 5310 NLGI No 1 Removal steps 4Ab 1 Rear speed sensor 2 O ring 3 Rear brake assembly 4 Rear brake disc B C 9 Self locking nut 10 4Cb Companion flange 11 Rear axle shaft 12 Adjusting wheel spring...

Page 956: ...C AXLE SHAFT ASSEMBLY REMOVAL With the special tool remove the axle shaft from the trailing arm INSTALLATION SERVICE POINTS A4 SHOE TO ANCHOR SPRING INSTALLATION The shoe to anchor spring must be ins...

Page 957: ...d tighten the speed sensor at such position where the gap is as specified below over the entire circumference Standard value 0 2 O 7 mm 008 028 in INSPECTION CHECKING FOR UNUSUAL WEAR OF THE BRAKE LIN...

Page 958: ...NOTES...

Page 959: ...CONTENTS STEERING 37A 4 WHEEL STEERING SYSTEM 4WS 378 CWHEEL STEERING SYSTEM ACTIVE 4WS 37C 1 I 37 1 L STEERING NOTE Shaded groups in the above list are not included in this manual...

Page 960: ...37 2...

Page 961: ...proper service or maintenance of any component of the SRS or any SRS related component can lead to personal injuryordeathtoservicepersonnel from inadvertentfiringoftheair bag ortothedriverand passenge...

Page 962: ...41 49 When new belt is installed 7 5 9 0 30 35 3il pump pressure MPa psi Pressure gauge valve closed 7 5 8 2 1 067 1 166 Pressure gauge valve opened 0 8 l O 114 142 Oil pressure switch operating Oil...

Page 963: ...ng part Bellows Silicone grease As required Power steering fluid Automatic transmission fluid DEXRON II 0 9 dm3 95 qt Flow control valve Automatic transmission fluid DEXRON II As required Friction sur...

Page 964: ...37A 4 STEERING Snecial Tools SPECIAL TOOLS Preload socket General service TSB Revision...

Page 965: ...ce To press in the oil seal for the rack tool Oil seal installer MB991197 Bar long type General service tool To press in the oil seal for the rack MB991 202 General service Press fitting of rack housi...

Page 966: ...l circumference and check play Standard values steering wheel play with engine stopped 11 mm 43 in If the play exceeds the standard value remove steering gear box and check total pinion torque STEERIN...

Page 967: ...value check for play or ratcheting in ball joint If none of these it is still serviceable STEERING WHEEL CENTERING SIMPLIFIED STEERING WHEEL CENTERING Determining Steering Wheel s Off Center 1 For th...

Page 968: ...n center as possible PRECISION STEERING WHEEL CENTERING In general the tie rods are adjusted to steer the front wheels in the same direction that the steering wheel is off center If the steering wheel...

Page 969: ...Steering effort 35 N 8 Ibs or less Fluctuation allowance 6 N 1 3 Ibs or less STEERING WHEEL RETURN TO CENTER CHECK To make this test conduct a road test and check as follows 1 Make both gradual and su...

Page 970: ...d level changes considerably air bleeding should be done FLUID REPLACEMENT 1 Raise the front wheels on a jack and then support them with rigid racks 2 Disconnect the return hose connection 3 Connect a...

Page 971: ...he steering wheel to the left and right until there are no air bubbles in the oil reservoir 7 Confirm that the fluid is not milky and that the level is up to the specified position on the level gauge...

Page 972: ...verhaul the oil pump 6 Remove the special tools and then tighten the pressure hose to the specified torque 7 Bleed the system CHECKING THE PRESSURE UNDER NO LOAD CONDITIONS 1 2 3 4 5 6 7 Disconnect th...

Page 973: ...and then tighten the pressure hose to the specified torque 8 Bleed the system OIL PRESSURE SWITCH CHECK 1 2 3 4 5 6 7 8 Disconnect the pressure hose from the oil pump and then connect the special too...

Page 974: ...ROUP 52B Air Bag Module and Clock Spring A A4 2 Steering wheel 3 Lower column cover 4 Upper column cover 5 Knee protector Refer to GROUP 52A Instrument Panel 6 Lap cooler duct and foot shower duct 7 C...

Page 975: ...LATION SERVICE POINT A STEERING WHEEL INSTALLATION Line up the NEUTRAL mark of the clock spring with the mating mark before installing the steering wheel Caution If the clock spring s mating mark is n...

Page 976: ...ylinder 213FOOSl 213FOO58 00002169 A 5 Special bolts A A 6 Steering lock bracket A A4 7 Steering lock cylinder 8 Steering column assembly TSB Revision DISASSEMBLY SERVICE POINT dAbSTEERING LOCK BRACKE...

Page 977: ...The steering lock bracket and bolts must be replaced with new ones when the steering lock cylinder is installed B BEARING INSTALLATION 1 Fill the inside of the bearing with multipurpose grease 2 Insta...

Page 978: ...ne Bleeding Refer to P 37A 1 I l Steering Wheel Position with Wheels Straight Ahead Checking l Front Wheel Alignment Adjustment Refer to GROUP 33A On vehicle Service 35 Nm 25 ft lbs 15 Nm 11 ft lbs ZU...

Page 979: ...the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque Standard value 0 6 1 3 Nm 5 11 in lbs NOTE Measure the pinion torque through the whole stroke of the rack If...

Page 980: ...ws W W 7 Tab washers N 8 Tie rods 9 Feed tubes 10 O rings FM4 l Total pinion torque adjustment 4D bL4 11 End plug 12 Self locking nut 4Eb 13 Locking nut 14 Rack support cover 15 Rack support spring 16...

Page 981: ...XRON II Z13POO77 21310564 Sealant 3M ATD Part No 8663 or equivalent 213G0070 Grease Silicone grease I Fluid Automatic transmission fluid DEXRON II Sealant 3M ATD Part No 8663 or equivalent J Z13N0019...

Page 982: ...VAL Using a screwdriver or similar tool loosen and then remove the boot retaining band C TAB WASHER REMOVAL Unstake the tab washer which fixes the tie rod and rack with a chisel D END PLUG REMOVAL Dis...

Page 983: ...from the valve housing simultaneously dH CIRCLIP REMOVAL 1 Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing 2 Turn the rack stopper anticlockwise...

Page 984: ...gear housing Caution Be careful not to damage the inner surface of the rack cylinder of the gear housing REASSEMBLY SERVICE POINTS bAdBACK UP WASHER OIL SEAL INSTALLATION 1 Apply a coating of the spe...

Page 985: ...ACK INSTALLATION 1 Apply a coating of multipurpose grease to the rack teeth face Caution Do not close the vent hole in the rack with grease 2 Cover rack serrations with special tool 3 Apply specified...

Page 986: ...I BALL BEARING INSTALLATION Apply a coating of the specified fluid to the outside of the ball bearing Using the special tools press the ball bearing into the valve housing Specified fluid Automatic tr...

Page 987: ...upport cover 30 60 and adjust torque to the standard value Standard value O 6 1 3 Nm 5 11 in lbs Caution 1 When adjusting set the standard value at its highest value 2 Assure no ratcheting or catching...

Page 988: ...ack for bends PINION AND VALVE ASSEMBLY CHECK l Check the pinion gear tooth surfaces for damage or wear l Check for worn or defective seal ring BEARING CHECK l Check for roughness or abnormal noise du...

Page 989: ...Pump Pressure Checking Refer to P 37A 12 Removal steps 1 Drive belt 2 Suction hose A 3 Pressure hose 4 O ring 43 N m 31 ft lbs Nm ft lbs Zl3NOO29 5 Pressure switch connector 6 Oil pump INSPECTION 7 Oi...

Page 990: ...Nm 16 22 ft lbs Zl3N0031 00002179 6 Disassembly steps 1 Pump cover E 5 D 5 j Cam ring C 6 Side plate A 7 O ring 8 Connector A 9 O ring 10 Flow control valve 11 Flow control spring 12 Terminal assembl...

Page 991: ...r No I D x Width mm in 1 11 x 1 9 433 x 075 2 13x 1 9 512x 075 3 17 8 x 2 4 701 x 094 4 13 5 x 1 5 531 x 059 5 3 8 x 1 9 150x 075 6 16 8 x 2 4 661 x 094 B SPRING INSTALLATION Fit the spring to the oi...

Page 992: ...g for wear l Check the shaft of the pulley for play and round movement l Check the groove of rotor vane for stepped wear l Check the contact surface of cam ring and vanes for stepped wear l Check the...

Page 993: ...8 ft lbs _ 12 Nm 15 Nm 11 ft lbs Removal steps 1 Return hose 2 Suction hose 3 Return hose l 2 9ure hose Z13N0060 White line Z13PO143 mFoo2s 6 Cooler tube 7 Pressure tube 8 Return tube 9 O ring 10 Oil...

Page 994: ...NOTES...

Page 995: ...LE SERVICE m m s m 4 Ball Joint Rotation Starting Torque Check 5 Bleeding 4 Function Check 5 Rear Oil Pump Discharge Flow Volume Check 5 SPECIAL TOOLS 2 SPECIFICATIONS 2 General Specifications 2 Lubri...

Page 996: ...Power cylinder tie rod swing torque N Ibs Nm in lbs 1 9 55 2 12 0 5 3 0 4 26 1 I Power cylinder slide resistance N Ibs 1 67 15 or less LUBRICANTS Items 1 Specified lubricant 1 Quantity Power steering...

Page 997: ...racks or deformation Feeling of friction in steering Poor steering return Steering wheel efforts exces Control valve Oil leakage from control valve joint sive Power cylinder Oil leakage from piston ro...

Page 998: ...d more 9 Start the engine and keep the front wheels in a straight ahead position Increase the engine speed once to a speedometer reading of 70 80 km h 43 50 mph to operate the oil pump for the rear wh...

Page 999: ...se speed slowly then hold the indicated speed of 50 km h 31 mph measuring discharge flow volume for 30 seconds Caution While performing this work continuously add fluid into the oil reservoir Standard...

Page 1000: ...fer to GROUP 37A On vehicle Service l 4WS System Bleeding Refer to P 37B 4 l 4WS System Operation Checking Refer to P 37B 5 l Wheel Alignment Checking Refer to GROUP 34 On vehicle Service 78 Nm 110 13...

Page 1001: ...full stroke to determine its neutral position 3 Align tie rod ends and the installation holes at trailing arm 4 When the tie rod ends and the installation holes at the trailing arm do not meet loosen...

Page 1002: ...lance as shown in the illustra tion Standard value 67 N 15 Ibs or less 3 If the slide resistance exceeds the standard value replace the power cylinder 4 If the slide resistance is less than the standa...

Page 1003: ...vice l Rear Suspension Assembly Removal Refer to GROUP 34 Rear Suspension Assembly L Post installation Operation l Rear Suspension Assembly Installation Refer to GROUP 34 Rear Suspension Assembly l Po...

Page 1004: ...WS System Operation Checking Refer to P 378 5 12 Nm 9 ft lbs Removal steps 1 Return hose 2 Suction hose 3 Protector 4 Pipe assembly to pressure tube connection 5 6 Pipe assembly Suction hose 213FOO24...

Page 1005: ...4 l 4WS System Operation Checking Refer to P 37B 5 110 130 Nm 80 94 ft lbs 80 94 ft lbs 213FOO2 t Removal steps 1 r shock absorber lower mounting 2 Crossmember bracket 3 Crossmember mounting nut 4 gt...

Page 1006: ...NOTES...

Page 1007: ...SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injuryordeathtoserviceperso...

Page 1008: ...ype Inner hinged with gas damper POWER WINDOW Power window motor Items Type Specifications Permanent magnet type Built in circuit breaker Revolutions under no load rpm Revolutions under At 1 Nm 72 ftl...

Page 1009: ...0 5 A after power connection SERVICE SPECIFICATIONS Items Standard value 1 Play of door inside handle mm in 1 A Way 1 7 28 I B OPEN 46 f 9 1 81 f 35 C FULL 69 2 72 Clearance of window glass to weathe...

Page 1010: ...n MB990834 MB990834 01 l x djusting Adjustment of door fit MB990449 EG P ld Removal of window moulding MB991 341 MB991341C Up to 1993 models Scan tool Checking the power windows system and the Multi u...

Page 1011: ...t locking and unlocking Uneven body clearance Uneven height Water leak through door window glass Water leak through liftgate window Door window mal function Water leak through door edge Water leak fro...

Page 1012: ...is discovered 4 When such a place is found cover it again and continue with the procedure so as to determine if there are any other noise sources 5 If no others are found the last remaining tape is th...

Page 1013: ...unit so that switch can be considered to be functioning normally If not the switch or switch input circuit is faulty Check the switch and the switch input circuit All models When using the scan tdol...

Page 1014: ...2 Door switch All doors close Door switch OFF Battery positive voltage One of doors open Door switch ON I o v 6 Door lock actuator L H LOCK I 5V 1 UNLOCK 9 Keyless entry control unit power source Igni...

Page 1015: ...ll be operated for a further 30 seconds If it is impossible l Malfunction of sunroof control unit the driver s door switch or the sunroof control unit may be defective l Malfunction of wiring harness...

Page 1016: ...No 7 and the sunroof control unit Repair if necessarv 3 NG Check the following connector E 45 NG c Repair NG Replace OK Measure at sunroof switch terminal Checkthe harness between the sunroof l Discon...

Page 1017: ...sen the hood latch mounting bolts and move the hood latch to adjust the attachment between the hood latch and hood striker LIFTGATE ADJUSTMENT 1 Loosen the liftgate hinges mounting bolts and then adju...

Page 1018: ...e door position along the body surface Caution Attach protection tape to the fender edges where the hinge is installed 3 If the door does not open freely adjust the engagement of the striker with the...

Page 1019: ...as shown in the illustration Weatherstrip Section A A Section B B 2 Section C C 218FO156 218FO155 moo1234 Adjustment Adjustment procedures Standard value mm in Adjust by turning the adjust Section A A...

Page 1020: ...the adjusting bolts of guide tracks 12 Adjust the delta sash so that the window glass end and the delta sash lip end are positioned as illustrated and tighten in position 13 Install the drip line wea...

Page 1021: ...window glass assembly 6 Tighten the stabilizer inner rear so that it presses against the window glass assembly 7 Check that the clearance between the weatherstrip holder and the top edge of the windo...

Page 1022: ...1 81 35 in C FULL 69 mm 2 72 in 2 If out of specifications adjust as described below 1 Remove the door trim Refer to P 42 42 2 Loosen the screw attaching the inside handle and slide the inside handle...

Page 1023: ...he water pressure so that water comes out of the hose to a height of approximately 50 cm 20 in when the hose is held vertically facing upwards 3 Hold the end of the hose about 30 cm 12 in above the ro...

Page 1024: ...LH 11 Hood side weatherstrip RH 12 Heat protector panel 13 Heat protector 14 Hood garnish assembly 15 Hood switch Vehicles with theft alarm system ZlRFO261 From 1994 models y 20 bs 7 ft lbs m v 8 ft...

Page 1025: ...CTION HOOD SWITCH CHECK Check the continuity between the terminals Switch position Terminal No 1 2 Lid switch unpressed 0 0 Lid switch depressed LIGHT SWITCH CHECK Turn the switch ON OFF and check con...

Page 1026: ...te and liftgate hinge removal steps l Washer tube Refer to GROUP 51 Windshield Wiper and Washer I b Nm 5 Nm 4 ft lbs 7 ft lbs Z18FO138 00002240 l Liftgate trim Refer to GROUP 52A Trims l Liftgate side...

Page 1027: ...52A Trims 11 Liftgate latch 12 Liftgate lock release cable Liftgate latch removal steps l Rear end trim Refer to GROUP 52A Trims 11 Liftgate latch Liftgate striker removal steps 0 Liftgate trim Refer...

Page 1028: ...illustration INSPECTION LIFTGATE LATCH SWITCH CHECK 1 Unlock the liftgate latch 2 Check the continuity between the terminals Switch position Terminal No 1 2 Liftgate latch locked Liftgate latch unloc...

Page 1029: ...ter Trim and Scuff Plate Remov al and lnstallatlon Refer to GROUP 52A Trims Adjustment l Fuel Filler Door Adjustment Refer to f 42 12 I Z18FOO68 i Z18FO130 Z18FOO85 Removal steps 1 Fuel filler door 2...

Page 1030: ...rt No 8625 or equivalent Z18FOO62 Section A A Fender Sealant 3M ATD Part No 8625 or equivalent Removal steps 1 Front splash shield l Side airdam Refer to GROUP 51 Aero Parts 2 Front splash shield 218F...

Page 1031: ...BODY Loose Panel 42 25 LOOSE PANEL REMOVAL AND INSTALLATION Air guide duct 18FO120 Liftgate gas spring r bracket 18FO124 Rear floor side member fiEfZE L z a xossmemuar TSB Revision...

Page 1032: ...AST URETHAN PRIMER 8608 Wire dia x length Adhesive gun 3M ATD Part No 8906 Wiping rags Sealer Glass holder Windshield moulding Service Part Window dam Service Part One cartridge As required for cuttin...

Page 1033: ...ng upper and lower clips Apply primer amply on bonding surface and dry 3 minutes or more Glass side I When glass is reused When glass is replaced Cleaning bonding surface Scoopoutexistingadhesivecompl...

Page 1034: ...ces sary Be careful not to damage the coated surface 2 If the coated surface is damaged apply paint 4 Cut off the lower portion of a new moulding and install the moulding temporarily to check that it...

Page 1035: ...ROUP 52A Trims 2 Yellow White NOTE Vehicles with sun Section A Vehicles without sun roofj Section B Adhesive x 12 15 z 4 C Cut off nozzle end Section A Vehicles with sun roof Section C 6 Adhesive Adhe...

Page 1036: ...ass edge 5 Put matchmarks on the body and the glass 6 Using the special tool remove the windshield glass 7 Using a sharp knife scoop out existing adhesive from the body flange to 2 mm 08 in or less th...

Page 1037: ...pecified area of the windshield 2 Affix the window spacer lower to the specified area of the windshield 3 When replacing glass fit a new glass once to the body and put matchmarks on the body and glass...

Page 1038: ...he adhesive line up the match marks on the glass and body and force the glass lightly and evenly onto the body for complete fitting 9 Remove adhesive from around and on the glass and body surfaces usi...

Page 1039: ...LJ Pre removal and Post installation Operation l Quarter Upper Trim Removal and Installation Refer to GROUP 52A Trims l Center Pillar Garnish Removal and Installation Refer to GROUP 51 Garnishes and M...

Page 1040: ...Center Pillar Garnish Removal and Installation Refer to GROUP 51 Garnishes and Mouldings Zl8FOOO2 Q 218FO132 r I II Cut off nozzle tip mm in 218F0060 Section A Adhe 7 Adhesive 50 1 97 Section C Adhes...

Page 1041: ...tion to the bolt Caution Hold the window glass with the glass holders to prevent it from falling when the adhesive is cut through 4 Using a sharp knife scoop out existing adhesive from the body flange...

Page 1042: ...king sure it is applied without breaks or thin spots Caution 1 The primer is used to strengthen bonding power Make sure that it covers the surfaces completely Note that the primer if applied to thick...

Page 1043: ...and body surfaces using a spatula and wipe the surfaces clean 6 After the work installation of the glass allow to stand until the adhesive hardens Caution If an infrared lamp or other means are used...

Page 1044: ...allation Refer to GROUP 52A Trims 4A AA 21 SF0323 Section A mm in Section B 12 15 47 59 Adhesive Primer lfib 7 26 1 0 39 7 Section C 27 1 06 _I 12 15 10 39 8F0308 00002317 Adhesive 3M SUPER FAST URETH...

Page 1045: ...the liftgate glass 3 Apply a uniform coat of primer to the illustrated areas of the body and glass making sure it is applied without breaks or thin spots Adhesive 3M SUPER FAST URETHAN PRIMER 8608 or...

Page 1046: ...n the glass and body surfaces using a spatula and wipe the surfaces clean 8 After the work installation of the glass allow to stand until the adhesive hardens Caution If an infrared lamp or other mean...

Page 1047: ...s 2 From 1995 models 16FO206 00002320 Door assembly removal steps 1 Connection for door wiring harness connector 2 Spring pin 3 Door assembly 4 Upper hinge 5 Lower hinge Door check strap removal steps...

Page 1048: ...itch and check the continuity between the terminals Switch position Terminal No 1 2 3 Switch Open ON 0 A 0 Depressed OFF DOOR TRIM AND WATERPROOF FILM REMOVAL AND INSTALLATION Sealant 3M ATD Part No 8...

Page 1049: ...AND INSTALLATION Adjustment l Door Window Glass Adjustment Refer to P 42 12 218FO200 00002323 Removal steps l Door trim Refer to P 42 42 l Waterproof film Refer to P 42 42 1 Delta cover inner 2 Delta...

Page 1050: ...outerweatherstrip Refer to P 42 63 3 up stop 4 Stabilizer inner front 5 Stabilizer inner rear 6 Delta sash 7 Door window glass 8 Door window regulator assembly 9 Door glass guide track front 10 Door...

Page 1051: ...terminal and check that the slider moves smoothly 2 Connect the battery in reverse polarity and check that the slider moves in opposite direction CIRCUIT BREAKER CHECK INCORPORATED IN THE POWER WINDO...

Page 1052: ...ection table Switch position Terminal No Power window switch I Driver s side switch I Passenger s side switch 1 v UP 0 0 0 0 Power 0 0 window lock OFF 0 n 0 0 0 switch lock DOWN 0 0 0 0 o 0 Door lock...

Page 1053: ...ion Refer to P 42 42 3 6 ZlSFO202 OoooP325 ZlSFOO41 Door inside handle removal l Door inside handle play check Refer to P 42 16 1 Door inside handle Door outside handle and latch removal steps 2 Door...

Page 1054: ...and there is continuity when it is turned further From 1994 models Insert the key and turn it to the LOCK or UNLOCK position to check for continuity as follows Vehicles with central door locking syste...

Page 1055: ...e terminal 3 for driver s side or 1 for passen ger s side and check to see that when the terminal l for driver s side or 3 for passenger s side is grounded the rod moves to the UNLOCK position 2 Then...

Page 1056: ...r continuity in accordance to the following connection table Vehicles with power window Power window main switch side Power window sub switch side Vehicles without power window l UNLOCK 0 0 DOOR LOCK...

Page 1057: ...BODY Central Door Locking System 42 51 i 4 Check for continuity between terminals under the condi tions described below Continuity no voltage TSB Revision...

Page 1058: ...STEM From 1993 model REMOVAL AND INSTALLATION ZlSF0317 Removal steps l Quarter trim L H Refer to GROUP 52A Trims 1 Antenna 2 Light automatic shut off unit 3 Rear intermittent wiper relay 4 Door lock p...

Page 1059: ...itter water dust etc may enter the transmitter resulting in transmitter troubles SECRET CODE REGISTERING METHOD Up to 1995 models The transmitter has each individual secret code stored in memory When...

Page 1060: ...ceiver is replaced or cause of the trouble is presumed to be due to faulty registration of the code Since two different codes at the most can be memorized in the memory space of EEPROM the old code wi...

Page 1061: ...t one was completed 6 After the second registration is completed the door will be locked and unlocked once 7 Registration mode finishes under the following conditions l Registration of two transmitter...

Page 1062: ...inge 6 Roof lid glass A4 7 Roof inner weatherstrip 8 Roof lid female hinge 9 Deflector Front of vehicle 219FO203 Roof lid regulator assembly removal steps 1 Sunroof trim assembly 2 Roof lid glass asse...

Page 1063: ...i 7 4 6 8 Roof lid removal steps 1 Roof lid trim 2 Roof lid 3 Roof lid weatherstrip Sunroof switch removal steps 4 Cover 5 Sunroof switch panel assembly 6 Sunroof switch A18FO389 Slide tilt ECU remova...

Page 1064: ...Front holder 14 Rear holder 15 Slide rail 16 Lifter assembly 17 Slider assembly 18 Rear timing 19 Tube cover 20 Drive unit assembly A18FO390 Frame assembly removal steps A 1 Roof lid trim A 2 Roof li...

Page 1065: ...the passenger compartment INSTALLATION SERVICE POINTS A DRAIN HOSE INSTALLATION 1 Tie the cord which has been used for removal again to the end of the drain hose and wind tape around the tie until it...

Page 1066: ...connection Tilt of roof lid SLIDING FORCE OF SUNROOF MOTOR S CLUTCH CHECK 1 Insert the sunroof wrench of the on board tools into the hexagonal hole in the motor drive shaft and hook a spring balance a...

Page 1067: ...mit switch B OFF 2 Check the identification colors Then install the limit switches as shown in the illustration ROTATION SENSOR CHECK 1 When connecting an ohmmeter negative probe to terminal 3 and the...

Page 1068: ...42 62 BODY Sunroof SUNROOF SWITCH CONTINUITY CHECK 18FO403 TSB Revision...

Page 1069: ...p front 4 Door inner opening weatherstrip rear 5 Door opening weatherstrip lower Drip line weatherstrip removal steps 6 Drip line weatherstrip 7 Door weatherstrip holder REMOVAL SERVICE POINT A DOOR O...

Page 1070: ...NOTES I...

Page 1071: ...MIRROR 31 SPECIAL TOOLS 4 FRONT BUMPER 8 SPECIFICATIONS 2 GARNISHES AND MOULDINGS 15 Adhesives 4 General Specifications 2 ON VEHICLE SERVICE 7 Service Specifications 4 Active Aero System Check 7 TROU...

Page 1072: ...e Nm ft lbs REAR WIPER MOTOR Items Type Braking system rpm at load of 0 6 Nm 0 43 ftlbs Specifications Ferrite magnet type Dynamic braking system 38f5 WINDSHIELD WIPER BLADE REAR WIPER BLADE Items Wip...

Page 1073: ...age drop at 12V Wiper switch and the rated load V Washer switch Specifications 4 0 22 0 05 Max 4 0 2 or less 0 5 or less REAR WIPER AND WASHER SWITCH i Items Specifications Rated load A Wiper switch W...

Page 1074: ...tool Window moulding remover MB991 341 MB991341C Scan tool Multi use tester MUT ROM pack Forthe number refer to GROUP 00 Precau tions Before Service MB991 502 MB991 502 Scan tool MUT II ROM pack MB99...

Page 1075: ...ch switch are being input to the ETACS unit 1 Connect the scan tool to the data link connector or connect the voltmeter between the ETACS terminal and the ground terminal 2 Check if the buzzer of the...

Page 1076: ...tch beforehand whenever the scan tool is connected or disconnected 3 The ECU input signal of individual circuit systems is nor mal if the scan tool buzzer sounds once when the respec tive switches are...

Page 1077: ...nds and then goes out 2 If the front venturi skirt does not return to the standard condition properly in normal use the warning light comes on 2 INSPECTION BY ACTIVE AERO SWITCH AT AUTO 2 1 With the v...

Page 1078: ...can tool is connected or disconnected 2 Turn the ignition switch to ACC or ON 3 Place the active aero switch to AUTO 1 4 Using the scan tool increase the vehicle speed to approx 80 km h 50 mph or more...

Page 1079: ...aero system 3 Side cover panel Vehicles with active aero system 4 Front cover panel Vehicles with active aero system 5 Center cover panel Vehicles with active aero system A 6 Front under cover panel V...

Page 1080: ...active aero system 5 Center cover panel Vehicles with A active aero system 6 Front under cover panel Vehicles with active aero system 7 Front splash shield extension 8 Fog light 9 License plate bracke...

Page 1081: ...mper face outer corner plate From 1994 models 4 Bumper face inner corner plate From 1994 models 5 C corner plate From 1994 models 6 Bumper face upper front plate 7 Bumper face upper center plate 8 Bum...

Page 1082: ...a 3 mm 13 in diameter hole to discharge the gas contained in the unit Be sure to wear safety goggles while performing this operation as the gas is not harmful but chips may be ejected with it 3 If the...

Page 1083: ...e inside of the bumper to remove the clip 2 Installation With the grommet inserted in the hole press the screw in Pre removal and Post installation Operation l Rear End Trim and Rear Side Trim Removal...

Page 1084: ...ffler plate 4 Bumper face 4Ab 8 Bumper reinforcement stay 9 Bumper absorber 10 Bumper reinforcement DISASSEMBLY SERVICE POINT dA BUMPER ABSORBER REMOVAL Caution 1 Do not attempt to repair a bumper abs...

Page 1085: ...indshield moulding Refer to GROUP 42 Windshield Liftgate moulding removal Hatchback 6 Liftgate moulding Refer to GROUP 42 Liftgate Glass Rear 218FO337 Front 9 Z18FO178 00002336 Adhesive tape 3M ATD Pa...

Page 1086: ...e garnish 4 When the side garnish is fastened with a clip or bolt pull the side garnish toward you to remove the clip or the bolt Caution 1 To reuse the side garnish remove it by pulling the fishing l...

Page 1087: ...he pressure sensitive double sided tape to 40 to 60 C 104 to 140 F for 5 to 10 minutes Caution Do not overheat the tape until its surface dries to turn white 2 Using a resin spatula or gasket scraper...

Page 1088: ...removal 2 With its clips and bolts aligned with the respective holes in the body install the side garnish to the body NOTE If it is hard to affix the pressure sensitive double sided tape in winter hea...

Page 1089: ...or equivalent m Adhesive 3M ATD Part No 8609 SUPER FAST URETHAN or equivalent Side air dam removal steps l Front splash slhield Refer to GROUP 42 Fender l Quarter trim Refer to GROUP 52A Trims A B 1...

Page 1090: ...gate lower trim Refer to GROUP 52A Trims 2 Rear spoiler assembly 4 High mounted stop light Front under cover panel air dam link assembly removal steps 5 Side cover panel L H 6 Front cover panel 7 Cent...

Page 1091: ...ure as the side garnish refer to P 51 15 provided that specified adhesive is used Specified adhesive 3M ATD Part No 8609 SUPER FAST URETHAN or equivalent INSPECTION 1 REAR SPOILER MOTOR AND LIMIT SWIT...

Page 1092: ...e operate freely 2 While performing the inspection described in 1 above check the limit switch for continuity Linkage position 1 Termi lNo 4 1 1 UP standard position b OI During operation 1 1 I DOWN o...

Page 1093: ...ive tape Ul ATD Part No 6382 or equivalent Standard position of motor Gear for limi switch zlAFO27CI Allen wrench 218F0267 I I i A MOTOR INSTALLATION 1 Make sure that the motor is in the standard posi...

Page 1094: ...ble assembly the drive gear of the motor may not engage with the cable In such a case they can be engaged with each other by tightening the motor mounting screw Bd MOTOR AND CABLE ASSEMBLY INSTALLATIO...

Page 1095: ...t garnish RH 5 Hole cover 4Ab 6 Wiper motor 7 Linkage Wiper motor removal steps 1 Wiper blade A 2 Wiper arm 5 Hole cover 4Ab 6 Wiper motor Column switch wiper and washer switch removal 15 Column switc...

Page 1096: ...ification symbol 2 After the wiper blades have been set install them in such a way that the ends of the wiper blades will stop at the specified positions standard values Standard value A 15 20 mm 6 8...

Page 1097: ...002342 21 EN0075 Wiper and Washer Switch Check Operate the switch to check for continuity between the termi nals Switch position I Terminal No I 3 4 5 6 7 8 9 1 0 Wiper OFF 0 0 switch INT 0 0 0 I I I...

Page 1098: ...Washer tank removal steps l Rear end trim Refer to GROUP 52A Trims 5 Cap 6 Washer tank 7 Washer motor 4Ab Quarter upper trim RH Refer to GROUP 52A Trims Rear roof rail trim Refer to GROUP 52A Trims 0...

Page 1099: ...mic part INSPECTION WIPER MOTOR CHECK Check the wiper motor with it mounted on the vehicle and with its harness connector disconnected Wiper Motor Operation Connect a battery to the wiper motor as sho...

Page 1100: ...elay connected to the wiring harness connector let the wiper operate intermittently and check the voltage at terminal 2 I Condition Standard 1 When wiper is stationary o v I When wiper is in operation...

Page 1101: ...ic remote controlled mirror switch Zl6FO16 9 B MIRROR REMOVAL Tilt the mirror upward and fit a screwdriver blade covered with protective tape in the notch between the mirror and the pivot plate to pry...

Page 1102: ...able when each terminal is connected to the battery 2 Check to see that there is continuity between terminals 1 and 5 ELECTRIC REMOTE CONTROLLED MIRROR SWITCH CHECK Operate switches and check for cont...

Page 1103: ...52 1 i INTERIOR CONTENTS INTERIOR 52A SUPPLEMENTAL RESTRAINT SYSTEM SRS 528 i...

Page 1104: ...52 2 NOTES...

Page 1105: ...ce or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especiall...

Page 1106: ...mounting bolts 1 3M Stud Locking Part No 41 70 or equivalent 1 L I I I SPECIAL TOOLS Tool g the seat belt warning light and buzzer Checking the seat belt warning light and buzzer MB991 529 Diagnostic...

Page 1107: ...needle of the voltmeter moves when each switch is operated if the buzzer sounds or the needle moves the input signals are being input to the ETACS unit so that switch can be considered to be functioni...

Page 1108: ...dels When a voltmeter is used Connect a voltmeter to the ETACS terminal and the ground terminal of the data link connector using the special tool Observe the voltmeter pointer deflection to read out t...

Page 1109: ...below are used They are indicated 1 by symbols in the illustration id Name Symbol Size mm in PxL Color I Shape E Washer assembled F screw 4x16 16x 63 5x16 20x 63 G 4x12 16x 47 I 6 x 16 24x 63 J 6 x 20...

Page 1110: ...garnish B 4 Knee protector assembly 5 Column cover 6 Glove box striker 4W 7 Glove box and cross pipe cover 9 Center air outlet assembly 10 Heater control assembly installation screws 219FO131 0000234...

Page 1111: ...cedures of GROUP 528 Air Bag Module and Clock Spring J I 00 3 2 Removal steps 1 Hood lock release handle 2 Rheostat 4Ab 3 Switch garnish B 4 Knee protector assembly 5 Column cover 6 Glove box striker...

Page 1112: ...clips of the center air outlet assembly with a fiat tip screwdriver remove the center air outlet assembly with the trim stick C SPEEDOMETER CABLE ADAPTER MECHANICAL TYPE SPEEDOMETER REMOVAL 1 Disconne...

Page 1113: ...box 1 I r f t 4 Instrument panel disassembly steps 7 Glove box lower frame Refer to GROUP 55 Ventilators l Side air outlet Refer to GROUP 55 Ventilators l Photo sensor Refer to GROUP 55 Ventilators e...

Page 1114: ...nish 9 Manual transaxle shift lever knob 5 Radio 10 Front console assembly DISASSEMBLY AND REASSEMBLY Front console disassembly steps 1 PJT garnish A T 2 M T shift lever cover M T 3 Ashtray 4 Cigarett...

Page 1115: ...river to push inward the pin at the center of the trim clip to a depth of about 2 mm 08 in 2 Pull the trim clip outward to remove it Caution Do not push the pin inward more than necessary be cause it...

Page 1116: ...rim Front pillar trim removal steps 4 Hanger bracket 5 Sasli guide cover mounting bolt 6 Clip 7 Front pillar trim NOTE 1 0 Location of metallic clip 2 C Location of resin clip 3 indicates trim clip Re...

Page 1117: ...bly 13 Shelf catcher 14 Cover 15 Garnish 16 Sash guide cover mounting bolt 17 Front seat belt anchor plate mounting bolt 18 Retractor cover 19 Rear seat belt anchor plate mounting bolt 20 Screw 21 Qua...

Page 1118: ...oor positively LHole iEm_ 1 REMOVAL AND INSTALLATION Luggage compartment 8 karter trim 4 A 1 0 Rear end trim B B Clip 219FOO47 Rear side trim rear end trim removal steps 1 Luggage compartment floor bo...

Page 1119: ...m 219FOO16 D D 1 E Liftgate side trim 219FO173 7 r Liftgate trim removal steps 1 Shelf hook 2 Liftgate lower trim 3 Liftgate upper trim 4 Liftgate side trim 3 BJ Clip NOTE 1 e Location of metallic cli...

Page 1120: ...ip 19FO283 Removal steps 1 Hanger bracket 2 Sash guide cover mounting bolt 3 Clip 4 Interior temperature sensor 5 Sunvisor assembly 6 Sunvisor holder 7 Room light assembly 8 Regulator cover Vehicle wi...

Page 1121: ...s center line CAUTIOPI SRS When removing and installing the floor console as sembly don t allow any impact or shock to the SRS diagnosis unit Standard type f Y A 1 eSnartv tvnab 1 Head restraint Front...

Page 1122: ...tration Refer to procedure 2 1 Procedure for removal and installation of seat stopped at forward position 1 Working from behind the seat remove the bolt from under the seat cushion as illustrated 2 In...

Page 1123: ...1 1 TSB Revision ront seat forward installation bracket Fe hard tab 1 A A kross c e ion ZlQFoom INSTALLATION SERVICE POINTS A FRONT SEAT ASSEMBLY INSTALLATION 1 Locate the lower rails correctly so th...

Page 1124: ...3 Insert the rear tab of the rear seat anchor cover in the front seat rear mounting bracket positively Then rotate the cover in the direction of arrow to install the side tabs in the side holes of the...

Page 1125: ...seat 6 Side shield cover L H 9 Side shield cover R H _ A 10 Inner seat belt 11 Seat cushion assembly Sporty seat 19 n 219FO192 00002359 12 Memory reclining knob 13 Sliding adjuster knob 14 Seat back p...

Page 1126: ...Seat back panel 15 Seat back assembly 16 Seat belt guide 19 Head restraint guide 24 Walk in knob 25 Walk in knob garnish 26 Slide adjuster REASSEMBLY SERVICE POINT pm ll fl q j i Harness Locmg claw A...

Page 1127: ...CHECK 194 Rear height motor rg 219F0199 00002360 1 Disconnect each motor at the connector To disconnect the lumbar support and side support motors remove the seatback panel in advance 2 Connect the t...

Page 1128: ...isconnect each limit switch at the connector and connect a circuit tester between the terminals 2 Operate each switch to check for continuity between the terminals 3 If there is any abnormality replac...

Page 1129: ...AL SERVICE POINT qA REAR SEAT CUSHION REMOVAL With the lever pulled raise the seat cushion and remove the seat cushion INSTALLATION SERVICE POINT A4 REAR SEAT CUSHION INSTALLATION 1 Fit the attachment...

Page 1130: ...shock to the SRS 45 Nm 33 ftlbs s Outer seat belt removal steps 1 Quarter trim Refer to P 52A 13 C 2 Outer seat belt Inner seat belt removal steps l Floor console assembly Refer to P 52A 10 3 Shield...

Page 1131: ...t iotation YlQFO12Q INSTALLATION SERVICE POINTS A4 OUTER SEAT BELT INSTALLATION 1 Positively insert the pawl to prevent the retractor from rotating in the hole provided on the body 2 Install the ancho...

Page 1132: ...e belt guide in the hole provided on the body 4 Install the final anchor of the front seat belt with the belt twisted 180 at the section between the sash guide and the final anchor so that the tip of...

Page 1133: ...rvice Specification 21 SRS DIAGNOSIS UNIT SDU 71 TEST EQUIPMENT 23 TROUBLESHOOTING 23 Diagnostic Sequence 24 SRS Diagnostic Procedures Initial Steps 23 CAUTION I l Carefully read and observe the infor...

Page 1134: ...t impact sensors simulta neously activate while the ignition switch is in the ON position These sensors are designed to acti vated in frontal or near frontal impacts of moderate to server force Only a...

Page 1135: ...front impact sensor SRS diagnosis unit Incorporated safing 19FO138 00004055 VEHICLE y 19FOO73 0020008 19FO118 NOTE This construction diagram displays the general view of the SRS components For detail...

Page 1136: ...I I Rightfront impact sensor Passkger s side 19FO244 19FO241 SRS diagnosis unit Incorporated safing imnsrt cancnri 19FO230 00004054 NOTE This construction diagram displays the general view of the SRS...

Page 1137: ...ions when servicing Shown here are the contents of the caution labels SRS attached to a vehicle from 1994 model On caution If labels are dirty or damaged replace them with labels attached to 1992 and...

Page 1138: ...rst start the vehicle see your dealer for If defective remove and replace entire unit per service manual service instructions See your owner s manual for more information Before replacement read servi...

Page 1139: ...I Crank signal detection circuit 1 IGNITION SWITCH IGl I Multi purpose fuses Connector lock switch r Combina 1 tion meter SRS wam ing light L Warning light malfunction detection circuit sensor Frc 1 I...

Page 1140: ...ock switch I r malfunction detection circuit UNLOCK 1 Connector lock detection circuit I I I D C DC converter u I I m ti VI LI t rl ib u m 0 Safing impact sensor Front impact sensor R H ON m FF Front...

Page 1141: ...A 09X f l 38 A 09X Starter relay A 38 Front impact sensor L H A 63 Front impact sensor R H B Engine and transaxle Front view B 23 Starter motor B 24 Starter motor B 26 Park neutral position switch NO...

Page 1142: ...1 00002555 D 26 Combination meter For SRS warning light Combination meter For SRS warning light Combination meter For SRS warning light 14 pin red connector to body wiring harness e pin blue connector...

Page 1143: ...osis unit side connector is pressed down until a click is heard indicating that the connectors have been locked Second ary lock If the harness and SRS diagnosis unit connectors do not properly fit the...

Page 1144: ...plies monitoring current to the circuit to electrically verify that the connectors have been locked CONNECTOR SHORTING MECHANISM The mechanism is designed for prevention of accidental igni tion of the...

Page 1145: ...IlY THEFT I ggy RLAEU I FM I ION H 1992 MODEL g g y 1993 MODEL z IGNITION SWITCHtIGl 2B W COMBINATION METER SRS WARNING LIGHT 8 CRANKING SIGNAL DETECTION CIRCUIT DRIVE CIRCUIT t L IIIIIIIIIII Y 93 z m...

Page 1146: ...eplace wiring if necessary after reading and following all precautions and procedures in this manual 2 Do not use an analogue ohmmeter to check SRS wiring or components use only special tools and digi...

Page 1147: ...Y 1 25B Y i MFI SYSTEM XWING 0 85B 2B Y 2B Y L 4LARM g 4RM 2B Y I8 LTp PARK NEUTRAL I 2B Y 2B Y 28 R rr STARTING 0 858 F M T A T t lm 0 858 Y MFI SYSTEM CONNECTOR 1 I A 1IX R B n r 7 I I i R LIGHT 1 l...

Page 1148: ...in this manual 2 Do not use an analogue ohmmeter to check SRS wiring or components use only special tools and digital multi meter shown on page 528 22 IGNI SWiT 0 w 2B W 63 IOA 0 833 k 0 858 R ON I IG...

Page 1149: ...PONENT LOCATION Name Symbol Name Symbol Data link connector From 1994 models D Front impact sensor A Data link connector Up to 1993 models C SRS diagnosis unit B 1 cur to 1993 models L YlQFO243 From 1...

Page 1150: ...age 52B 681 4 Do not attempt to repair the wiring harness connectors of the SRS If any of the connectors is diagnosed as fault replace the wiring harness If the wires are diagnosed as faulty replace o...

Page 1151: ...impact sensor L H To front impact sensor R H harness 14 pin 2 pin blue connector to right front impact sensor SDU e pin yellow connector to left front impact sens 2 pin red connector to clock spring Y...

Page 1152: ...estination of Harness Body wiring harness Junction block Body wiring harness Ground NOTE 1 The sensor cable marked with is available as service part 2 The sensor cable used as a replacement part is ro...

Page 1153: ...rk is done on the SRS system immediately after the battery cables are disconnected 6 SRS components should not be subjected to heat over 93 C 2OO F so remove the front impact sensors SRS diagnosis uni...

Page 1154: ...ing diagnostic trouble code l Reading trouble period l Reading erase times l Reading diagnostic trouble code l Erasing diagnostic trouble code Reading trouble period l Reading erase times SRS check ha...

Page 1155: ...ition Does SRS warning light illuminate for about 7 seconds and then turn OFF If yes SRS system is functioning properly If no continue with following steps NOTE 1 From 1993 model the SRS warning light...

Page 1156: ...the displayed diag nostic trouble codes and service data fault duration and how many time memories are erased using the scan tool NOTE 1 Maximum stored period 9999 minutes approximately 7 days 2 Maxim...

Page 1157: ...s air bag module squib are shorted to Perfom TEST 6 each other or the circuit is grounded 22 The driver s seat air bag module squib circuit is open or the wire from the driver s air bag module to the...

Page 1158: ...rminal with sulation Then charge NOTE IMPORTANT 1 After repairing the SRS reconnect the battery cable erase the diagnostic trouble code memory from the scan tool and check the SRS warning light operat...

Page 1159: ...p to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the ba...

Page 1160: ...se excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a notch on the lock lever Type 2 Place a flat t...

Page 1161: ...trument panel wiring harness Check for continuity between the grouna and terminal No 12 or No 13 of the body wiring harness s connector which is con netted to the instrument panel wiring bar ness yes...

Page 1162: ...93 models 2 From 1994 models J 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the bat ter...

Page 1163: ...rd the inside of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a n...

Page 1164: ...al 2 After waiting at least 80 seconds repair or reDiaCethebodvwiring harness Reier to P 528 18 20 1 Tum the ignition key to the LOCK position disconnect the nega tive battery cable and tape the termi...

Page 1165: ...odule squib failure modes simultaneously occur in two places the preconditions for the respective detection circuits will go out of order For this reason both diagnostic trouble codes may not be store...

Page 1166: ...emove the rear console assembly Refer to GROUP 52A Floor Console 3 Apply a flat tip screwdriver to the lock spring metallic portion of the SDU connector lock lever as illustrated and push it horizonta...

Page 1167: ...impact sensor normal I Yes c SRS check harness connector 5 is there continuitv between each of them and the body ground I IUO 1 CONTINUED ON NEXT PAGE 1Short circuit of the harness between left 1 w f...

Page 1168: ...Harness 2 Reconnect blue and yellow connectors for the wiring lead ing to the front impact sensors to the SDU and double lock them Refer to P 52B 11 NOTE If double locking cannot be made the connector...

Page 1169: ...erminals Passenger s air bag module To c ock spring To body wiring Zl9N0303 harness 14 pin 00002608 If combined front impact sensor and air bag module squib failure modes simultaneously occur in two p...

Page 1170: ...re In case that there is no notch on the lock lever Type 1 Place a flat tip screwdriver against the lock spring metal section of the connector lock lever as shown in the illustra tion and push the spr...

Page 1171: ...front impact sensor normal Replace the right front impact sensor t For terminals No 15 and No 18 of the SRS check harness connector 5 is there continuity between each of them and the body ground Yes t...

Page 1172: ...connector 1 of the SRS Check Harness 2 Reconnect 16pin red connectors for the wiring leading to the front impact sensors to the SDU and double lock them Refer to P 52B 11 NOTE If double locking canno...

Page 1173: ...s measured with a tester accidental driver s air bag deployment will result in serious personal injury L FUSIBLE LINK C IGNITION SWITCH IG1 SRS DIAGNOSIS UNIT t t 22 z El B d r c d G isi84FPG i I r Ic...

Page 1174: ...but only one of them may be indicatpd Their relationships are shown in the following table Perform TEST 5 if it does not become proper even through TEST 6 is executed Failure modes Front impact Front...

Page 1175: ...GROUP 52A Floor Console 3 Release the lock of SDU connector in accordance with the following procedure In case that there is no notch on the lock lever Crwe 1 Place a flat tip screwdriver against the...

Page 1176: ...de connector of the SDU which were connected to the driv er s air bag module squib through the clock spring NOTE A 3 ohm resistor that corresponds to the resistance of the driver s air bag module squi...

Page 1177: ...o 1993 model use the adapter harries supplied together Caution Before connecting or disconnecting the scan tool make sure that the ignition switch is placed at tht OFF position 3 Turn the ignition key...

Page 1178: ...has been discon nected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected Apply a flat tip screwdriver t...

Page 1179: ...s the resistance between terminal 1 and terminal 21 of SRS Check Harness connector 5 and between termi nal 2 and terminal 22 of SRS Check Harness connector 5 normal Standard value less than 0 4 12 IYO...

Page 1180: ...uit resistance is measured with a tester accidental passenger s air bag deployment will result in serious personal injury FUSIBLE LINK Q IGNITION SYITCH IGI 1 7p PURPOSE Q 1 7 m i 2 8 1 2 R Hi r MO SR...

Page 1181: ...codes may not be stored but only one of them may be indicated Their relationships are shown in the following table Perform TEST 5 if it does not become proper even through TEST 7 is executed Failure...

Page 1182: ...fter the battery has been discon nected Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected Disconnect th...

Page 1183: ...ignition key from the ON to the LOCK position and then back to the ON position 1 Defective passenger s air bag module Replace passenger s air bag module Re fer to P 52575 Caution Never attempt to meas...

Page 1184: ...p to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the ba...

Page 1185: ...tally toward the inside of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that th...

Page 1186: ...cable and tape the terminal 2 After waiting at least 60 seconds repair or replace the body wiring har ness Refer to P52B 16 20 NOTE IMPORTANT 1 If more than 45 seconds of cranking is required to star...

Page 1187: ...he battery cable before doing any further work The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected Se rious injury may result from un...

Page 1188: ...NOTE harness 14 pin o l Up to 1993 models l 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds...

Page 1189: ...de of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a notch on the...

Page 1190: ...OCK position disconnect the negative battery cable and tape the terminal repair or replace the body wiring har Replace the SDU Refer to P 52B 64 ground and the No 11 terminal of Damagedordisconnectedw...

Page 1191: ...n OC NOTE l Up to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconn...

Page 1192: ...not use excessive force to raise the lock lever 4 Disconnect the red 14 pin connector from the SDU 5 Reconnect negative terminal of battery and turn the igni tion key to the ON position 6 Check accor...

Page 1193: ...ess 1Cpin OC I NOTE l Up to 1993 models 2 From 1994 models 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal Caution I Wait at least 60 seconds a...

Page 1194: ...Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring In case that there is a notch on the lock lever Type 2 Place...

Page 1195: ...m out SRS warning light bulbs or c damaged or disconnected body wiring harness 1 Turn the ignition key to the LOCK position disconnect the negative battery cable and tape the terminal 2 After waiting...

Page 1196: ...cted or disrupted by the collision the scan tool cannot communicate with the SRS diagnosis unit Inspect and if necessary repair the body wiring harness be fore proceeding further 3 Read the service da...

Page 1197: ...howing any visible damage such as dents cracks or deformation replace them with new ones Concerning parts removed for inspection replacement with new parts and cautionary points for working refer to a...

Page 1198: ...arness 3 Check air bag inflator case for dents cracks or deformities 4 Install air bag module to steering wheel to check fit or alignment with the wheel Passenger s side 1 Check module cover for dents...

Page 1199: ...ing wheel and con nectors for damage and terminals for deformities 2 Install air bag module to check fit or alignment with steering wheel 3 Check steering wheel for noise binding or difficult opera ti...

Page 1200: ...et metal repair painting etc they should be stored in a clean dry place until they are reinstalled FRONT IMPACT SENSORS Caution 1 Never repair or disassemble a front impact sensor If faulty replace it...

Page 1201: ...ted If a dent crack or other deformation or rust is detected discard the sensor and replace it with a new one that passes the visual inspection 2 Before any front impact sensor is installed in the veh...

Page 1202: ...for damage and terminals for deformities 3 Check for dents cracks or deformation of the front impact sensor Caution If a dent crack deformation or rust is detected re place with a new sensor 4 Remove...

Page 1203: ...is unit with a new one 4 Never use an ohmmeter on or near the SRS diagnosis unit and use only the special test equipment described on P 528 23 Y19FO130 I i 2 pin yellow connector to left front impact...

Page 1204: ...sh the spring horizontally toward the inside of the unit Caution 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock s...

Page 1205: ...unit D POST INSTALLATION INSPECTION Reconnect the negative battery terminal Turn the ignition switch to ON Does the SRS warning light illuminate for about 7 seconds turn OFF and then remain OFF for a...

Page 1206: ...AND INSTALLATION Air bag module driver s side clock spring Pre removal Operation l After setting the steering wheel and the front wheels to the straightahead position remove the ignition key I Up to...

Page 1207: ...s side Air bag module removal steps Passenger s side 4Ab F l Post installation inspection 1 Negative battery cable connection 12 Glove box assembly 13 Cross pipe cover 14 Air bag module passenger s s...

Page 1208: ...r bag module press the air bag s lock toward the outer side to spread it open Use a screwdriver as shown in the figure at the left to pry so as to remove the connector gently Caution 1 When disconnect...

Page 1209: ...INSPECTION Caution Dispose of an air bag module only according to the specified procedure Refer to P 528 82 to P 528 87 2 Connect the scan tool to the data link connector When connecting the scan tool...

Page 1210: ...ever of the SRS diagnosis unit D STEERING WHEEL INSTALLATION 1 Before installing the steering wheel be sure to first turn the vehicle s front wheels to the straight ahead position and align the mating...

Page 1211: ...efer to P 52B 82 P 52B 87 Caution Never attempt to measure the circuit resistance of the air bag module squib even if you are using the specified tester If the circuit resistance is measured with a te...

Page 1212: ...Up to 1993 and 1996 models Check for continuity between the No 1 connector of the I t i clock spring and connectors No 3 4 5 and 6 I Iesigna T o To To To To ion cruise ACC horn To steering To cruise...

Page 1213: ...the terminals a Join the No 2 connector air bag module side and No 7 connector of clock spring to connector 4 and connector 3 respectively of the SRS Check Har ness NOTE When joining SRS Check Harnes...

Page 1214: ...hen disposing a vehicle 1 Open all windows and doors of the vehicle Move the vehicle to an isolated spot 2 Disconnect the negative and positive battery cables from the battery terminals and then remov...

Page 1215: ...HARNESS A and cover the connections with insula tion tape The other ends of the two wires should be connected to each other short circuited to pre vent sudden unexpected deployment of the air bag 5 C...

Page 1216: ...vehicle Wear safety glasses suitable ear protection 2 The inflator will be quite hot immediately following the deployment so wait at least 30 minutes to allow it to cool before attempting to handle it...

Page 1217: ...four bolts at the back of air bag module and connect thick wires to these bolts to secure the module to the wheel 4 Pass SRS air bag adapter harness B connected with wires under the used tire wheel as...

Page 1218: ...be connected to each other short circuited to pre vent sudden unexpected deployment of the air bag 3 Connect the deployment wires to the SRS air bag adaptor harness A pass it beneath the tire and whe...

Page 1219: ...air bag module fails to deploy when the procedures above are followed do not near the module Contact your local distributor DEPLOYED AIR BAG MODULE DISPOSAL After deployment the air bag module should...

Page 1220: ...NOTES dl...

Page 1221: ...N NEXT PAGE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING 1 Improper service or maintenance of any component of the SRS or any SRS related component can l...

Page 1222: ...ment 18 Compressor Noise 28 Handling Tubing and Fittings 28 Idle up Operation Check 29 Performance Test 26 Power Relay Check 29 Refrigerant Leak Repair Procedure 28 Test Procedures 16 REFRIGERANT LINE...

Page 1223: ...lubricant FREOL S 83 or SUNISO 5GS SUN PAG 56 cc cu in 160 20 9 8f1 2 160 20 9 851 2 Drive belt size mm in 1 150 45 3 1 150 45 3 Dual pressure High pressure switch OFF 2 700 384 switch kPa psi OFF 3...

Page 1224: ...olution pick up sensor standard resistance Sz when ambient temperature is 20 C ter motor assembly resistance tiometer assembly r Engine coolant temperature Sensor ON temperature sensor C F 26 5 f 4 79...

Page 1225: ...1 386 Pin MIT217213 MB991 341 MB991 341 C Up to 1993 models Inspection of full auto air conditioning Scan tool Multi use tester MUT ROM pack For the num ber refer to GROUP 00 Precautions Be fore Servi...

Page 1226: ...etely connected crushed bent or clogged Adjust Repair or replace Burn out fuse Poor grounding Malfunction blower switch Correct Replace Replace 55 30 Malfunction resistor Malfunction blower motor Malf...

Page 1227: ...the engine and compressor exceed 92 for more than three seconds the A C compressor lock controller turns off the magnetic clutch relay which opens the mag netic clutch circuit 2 when a signal is rece...

Page 1228: ...A C ECU to activate the compressor warning indicator d The indicator will blink 4 The NC compressor lock controller does not contain a memory circuit It will operate the compressor and check for belt...

Page 1229: ...95 models Generator t Fuse Fuse Ignition coil 1 I 1 I n Fin therm0 sensor Air inlet sensor I A 1 Engine tprn calculation I NC compressor L calculation Circuit lock controller Y cl Fuse Resistor Heater...

Page 1230: ...I MH Heatercontrol panel I Pk J OFF WI Air conditioning switch I II 1 conditioning control unit 1 T 1 1 1 Fin therm0 sensor Air inlet C n I A I t Compressor rpm NC compressor calculation circuit lock...

Page 1231: ...osi tive voltage 6 Air conditioning compressor relay 7 Air conditioning switch A C When all conditions for switch ON of the Battery posi compressor are satisfied tive voltage When air conditioning swi...

Page 1232: ...switch ON System voltage power source A C switch indicator Compressor ON Normally 0 7 VDC 0 9 VDC Compressor drive belt 5 VDC Slipping slip ratio 92 or more Engine revolution input When engine is runn...

Page 1233: ...299 to 384 psi Correct places where gas leaks Gas leakage i 4 6 Dual pres sure switch Replace dual pressure switch Check for continuity be tween switch terminals Check for continuity be tween thermos...

Page 1234: ...e mineral oil handy when working on the refrigeration system Should any liquid refrigerant get into the eyes use a few drops of mineral oil to wash them out R 12 is rapidly absorbed by the oil Next sp...

Page 1235: ...y id when working on the refrigeration system Should any liquid refrigerant get into the eyes use a few drops of mineral oil to wash them out R 134a is rapidly absorbed by the oil Next splash the eyes...

Page 1236: ...the magnetic clutch 2 Connect battery to compressor body 3 Connect battery voltage directly to the wiring for the magnetic clutch 4 If the magnetic clutch is normal there will be a click If the pulley...

Page 1237: ...mal The magnet clutch is fre quently turned on and off The difference between the high and low pressures is not observed Abnormal Blow out tem perature is high Probable cause Faulty com pressor Faulty...

Page 1238: ...Vehicles using R l 2 refrigerant CHARGE EQUIPMENT INSTALLATION 1 Turn the adaptor valves 1 and 2 handles back fully valves shut and attach adaptor valves 1 and 2 to the high and low pressure service v...

Page 1239: ...ans Follow the safety precautions for handling R 12 as listed in this group TSB Revision CHARGING THE REFRIGERANT Vehicles using R l 2 refrigerant CHARGING WITH SMALL CANS When using disposable cans o...

Page 1240: ...e 1 handle fully clockwise valve open I j 1 Caution 1 m 1 If the service can is inverted liquid refrigerant may be drawn into the compressor damaging it by liquid Service can compression Keep the serv...

Page 1241: ...erant checking level with the sight glass 12 Upon completion of charging turn back the adaptor valve 2 handle all the way valve shut 13 Remove the adaptor valve 2 from the service valve NOTE If the se...

Page 1242: ...e vacuum pump 8 Connect the charging hose yellow to the R l 34a connec tion port of the vacuum pump adaptor 9 Tighten the adaptor valve handle valve open 10 Open the low pressure valve of the gauge ma...

Page 1243: ...the handle of the adaptor valve back all the way valve closed 21 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 1244: ...all the quick joint for low pressure to the low pressure service valve NOTE The low pressure service valve should be connected to the low pressure hose 8 Start the engine 9 Operate the air conditioner...

Page 1245: ...ING SYSTEM Too little oil will provide inadequate compressor lubrication and cause a compressor failure Too much oil will increase discharge air temperature When a compressor is installed at the facto...

Page 1246: ...control MAX COOL position Air selection Recirculation position Blower switch HI Fast position 8 Adjust engine speed to 1 000 rpm with air conditioning clutch engaged 9 Engine should be warmed up with...

Page 1247: ...the service valve until a click is heard When connecting run your hand along the hose while press ing to ensure that there are no bends in the hose 6 Start the engine 7 Set the A C controls as follows...

Page 1248: ...rged before opening any fitting of connection in the refrigeration system Open fittings with caution even after the system has been discharged If any pressure is noticed as a fitting is loosened allow...

Page 1249: ...he radiator fan motor relays HI and LO from the relay box on the right of the engine compartment 2 Remove the radiator fan motor relay air conditioning Up to 1993 models condenser fan motor relays HI...

Page 1250: ...2 Glove box outer case assembly Cd 3 Air selection control wire connection 4 Hood lock release handle 5 Rheostat assembly 6 Rear wiper and washer switch 7 Knee protector 8 Shower duct B 9 Mode contro...

Page 1251: ...wing the steps below 1 Move the mode selection lever to the defroster position 2 With the mode selection damper lever pressed inward in the direction indicated by the arrow connect the inner cable of...

Page 1252: ...ssor lock controller J zmPo011 00002624 I N S P E C T I O N RESISTOR CHECK Using a circuit tester measure the resistance between the terminals indicated below The condition can be considered satisfact...

Page 1253: ...ter air outlet assembly with a flat tip screwdriver remove the center air outlet assembly with the trim stick B AIR CONDITIONING SWITCH REMOVAL Remove the center air outlet assembly and insert hand to...

Page 1254: ...on 2 Center reinforcement 3 Under cover 4 Distribution duct foot 5 Foot shower duct 6 Lap cooler duct 22OFO104 4 7 Evaporator mounting bolt and nut 8 Vehicles with air conditioning Center duct 9 Heate...

Page 1255: ...the heater core for clogging and water leakage BLOWER ASSEMBLY REMOVAL AND INSTALLATION m 5 J 7 8 yy dT J Li w 66 6 Y 4 6 Pa 7 __ q ZZOFOO79 Blower case assembly removal steps 1 Stopper 2 Glove box 3...

Page 1256: ...er lever as it contacts stopper 3 Connect the inner cable of the air selection control wire to the end of the air selection lever and then secure the outer cable by using a clip INSPECTION l Check for...

Page 1257: ...wer frame 9 A C control unit Up to 1995 models A 10 Evaporator REMOVAL SERVICE POINT A DlSCHARGE PIPE C AND SUCTION HOSE B DISCONNECTION If the hoses or pipes are disconnected cap the hoses or pipes w...

Page 1258: ...case upper 9 Insulator 4 Fin therm0 sensor Up to 1995 10 Rubber insulator models 11 5 Air inlet sensor Up to 1995 models Clip with manual air conditioning 4B 12 Expansion valve DISASSEMBLY SERVICE PO...

Page 1259: ...odels I O ring w 3 Cf I t 70N0089 Compressor oil FREOL S 83 or SUNISO 5GS dehicles using R 12 refrigeranb SUN PAG 56 Vehicles using R 134a refrigerant Removal steps 1 Compressor drive belt 2 Condenser...

Page 1260: ...nt X cm3 X fl oz of oil within the removed compressor 2 Wipe away from the new compressor the amount of oil calculated according to the following formula and then install the new compressor New compre...

Page 1261: ...onsidered satisfactory if the operation sound a click sound of the magnetic clutch can be heard when this check is made Magnetic clutch disassembly steps 1 Bolts 2 Pulley A D 3 N u t C 4 Armature plat...

Page 1262: ...etic clutch disassembly steps 1 Bolts 2 Pulley A D 3 N u t C 4 Armature plate S ztr ring A4 CJ h coil High pressure relief valve disassembly 4B 12 High pressure relief valve Thermostat and revolution...

Page 1263: ...snap ring from inside the fitting block and remove the refrigerant temperature switch 3 Remove the revolution pick up sensor from the fitting block REASSEMBLY SERVICE POINTS A4 CLUTCH COIL INSTALLATI...

Page 1264: ...cracks or scoring on the sealing d surfaces l Check the compressor shaft for scoring HIGH PRESSURE RELIEF VALVE CHECK The high pressure relief valve is a safety feature which releases part of the refr...

Page 1265: ...ts a low pressure level during the operation of the air conditioning and adjusts the amount of refrigerant to be bypassed 1 Operate the air conditioning under a high temperature load condition when ve...

Page 1266: ...r oil FREOL S 83 or SUNISO 5GS Vehicles using R 12 refrigerant SUN PAG 56 Vehicles using R 134a refrigerant Removal steps d 9 Nm 7 ft lbs Z2OFOO28 00002630 1 Condenser fan motor assembly 2 Fan 3 Motor...

Page 1267: ...s using R 12 refrigerants SUN PAG 56 Vehicles using R 134a refrigerant Quantity 15 cm3 S fl 02 INSPECTION l l Check the condenser fan for crushing or other damage Check the condenser s discharge hose...

Page 1268: ...2 refrigerant SUN PAG 56 X20N0089 Vehicles using R l 34a refrigerant n 6 I 13 Nm 9 ft lbs 2 23 Nm 17 ft lb 13 Nm 9 11 Nm 7 8 ft lbs 12 15 Nm 9 11 ft lbs f3 i From Oct 1992 models IL 22OFO161 00002631...

Page 1269: ...cified amount of oil in the compressor before installing these parts in the vehicle Compressor oil FREOL S 83 or SUNISO 5GS Vehicles using R 12 refrigerant SUN PAG 56 Vehicles using R 134a refrigerant...

Page 1270: ...65 i Knee protector Refer to GROUP 52A Instrument Panel Foot shower duct Lap cooler duct Under cover A C compressor lock controller Side defroster hoses A Duct Vehicles without air conditioning Instru...

Page 1271: ...OINTS A PHOTO SENSOR REMOVAL Using the trim stick remove the photo sensor from the defroster garnish B CENTER AIR OUTLET ASSEMBLY REMOVAL Disengaging the clips 2 positions of the center air outlet ass...

Page 1272: ...AL AND INSTALLATION 13 Nm 9 4 ft lbs Inlet garnishes removal steps 1 Windshield wiper arm 2 Front deck garnish 3 Inlet garnish RH 4 Inlet garnish LH ZZOFOO98 00002632 Rear ventilation duct removal ste...

Page 1273: ...e coolant temperature switch xTk 22OAO199 INSPECTION AIR CONDITIONING ENGINE COOLANT TEMPERATURE SWITCH ALWAYS CLOSED TYPE CHECK 1 immerse the A C engine coolant temperature switch in oil and heat by...

Page 1274: ...Reference Chart to know the inspection items and then start the inspection procedure detailed in the following pages 6 When checking components be sure to disconnect the connectors first TROUBLESHOOT...

Page 1275: ...olant temperature switch Up to 1993 models Pressure switch Air conditionia control panel 4 3 3 3 Refrigerant amount Receiver Expansion valve Compressor 1 Thermostat I I I I T 1 A C compressor lock con...

Page 1276: ...A C compressor lock controller Defective MFI control unit Replace MFI control unit Defective interior temperature sensor Check on board diagnos input circuit tic output Defective blend air damper pot...

Page 1277: ...eiver 55 48 Clogged expansion valve Replace expansion valve 55 38 Defective compressor Replace compressor 55 39 Defective air inlet sensor Replace air inlet sensor 55 77 Defective magnetic clutch Repl...

Page 1278: ...control Condenser fan does Defective condenser fan motor relay Replace power relay 55 29 not operate when the air conditioning is acti Defective condenser fan motor Replace condenser fan 55 46 vated m...

Page 1279: ...adjust GROUP 11 Defective compressor drive belt Replace Defective compressor Check and replace 55 17 39 Defective revolution pick up sensor Check and replace 55 41 42 45 Defective air conditioning sw...

Page 1280: ...ltages Termtnal No Slgnal name Condmon Terminal voltage _ Connectors are keyed by terminal numbers I 55 1 Air inlet sensor 1 Temperature at sensor 25 C 77 F 4 kW I2 2 2 8V I 60 sensor power source Nor...

Page 1281: ...purpose fuse I r 1 I r m Air conditioning control unit Troubleshooting Hints l Air conditioning control unit terminal voltage Terminal No Signal name Condition Terminal voltage 53 Backup power source...

Page 1282: ...Fix air selection damper at FACE position or at FACE position when it is at FACE position l Air conditioning control unit terminal voltages Terminal No Signal name Condition Terminal voltage 56 Blend...

Page 1283: ...155 Troubleshooting Hints l Diagnosis No 11 12 Fix interior temperature sensor input signal at 25 C 77 F No 13 14 Fix air inlet sensor input signal at 15 C 59 F No 21 22 Fix air therm0 sensor input si...

Page 1284: ...ccm Fin speed arith pensatina circuit metic circuit t ND conversion ND conversion i Air conditioning tar drive wcuit power transistor L 69 22OFOl50 Z2OFO149 00002634 Troubleshooting Hints l Air condi...

Page 1285: ...ioning control unit Revolution pickup sensor j68 j61 j116 IG2 1 eecontrol Condenser fan motor relay LO I 7 Air conditioning compressor lock controller NC color monitor Blinking 22OFOO26 2OFO177 Operat...

Page 1286: ...r control motor circuits Blend air damper control motor Air conditioning Air inlet sensor Blend air damper control motor Z2OFO152 Mode selection damper control motor Air conditioning control panel Eng...

Page 1287: ...F 40 seconds after the damper moved to FACE position DEF switch ON tov Output turns OFF 40 seconds after the damper moved to DEE position Inside air switch ON 1ov Output turns OFF 40 seconds after ins...

Page 1288: ...r I I transis 4 I tor drive circuit ZZOFO158 Troubleshooting Hints l Air conditioning control unit terminal voltages Terminal No Signal name Condition Terminal voltage Air conditioning power transisto...

Page 1289: ...referring to diagnostic chart 3 Erase the failure code 4 Check the system again With voltmeter meter _ Y2OFO107 I Ground tya Diagnostic output l When using the voltmeter Up to 1993 models 1 Connect a...

Page 1290: ...models I Connect a voltmeter to the diagnostic output terminal and I the ground terminal of the data link connector using the special tool Read out the diagnostic trouble code by observing the voltme...

Page 1291: ...d air damper po tentiometer and air condi tioning control unit Replace blend airdamp er potentiometer Correct harness Poor connection of air conditioning control unit connector or defective air condit...

Page 1292: ...r or MAX COOL when it is at MAX COOL 32 n17n Short circuited and open circuited mode DEF selection damper potentiometer or FACE when it is at FACE u12A0107 41 nnnn Defective blend air damper motor 42...

Page 1293: ...l and Post installation Operation l Floor Console Removal and Installation Refer to GROUP 52A Floor Console CAUTION SRS When installing or removing the floor console don t allow any impact or shock to...

Page 1294: ...POWER TRANSISTOR AIR CONDITIONING COMPRESSOR LOCK CONTROLLER REMOVAL AND INSTALLATION t20F0073 Power transistor removal steps 1 Stopper 2 Glove box outer case assembly 3 Power transistor A C compress...

Page 1295: ...r conditioning control unit 6 Center outlet assembly zPOFOO77 7 Air conditioning control panel 8 Air conditioning control unit 9 Blend air damper motor assembly Mode selection damper motor assembly re...

Page 1296: ...does not turn when battery voltage is applied BLEND AIR DAMPER POTENTIOMETER CHECK Connect a circuit tester across terminals 5 and 6 of the motor assembly connector and check that resistance graduall...

Page 1297: ...FOO15 8 00002638 Engine coolant temperature sensor removal steps 2 Stopper e box outer case assembly 7 Engine coolant temperature sensor Air inlet sensor removal steps 2 Stopper 3 Glove box outer case...

Page 1298: ...he engine coolant tempera ture 2 Check that the engine coolant temperature sensor is con ductive when the engine coolant temperature reaches the specified temperature Standard value 26 5 4 C 79 7 f 7...

Page 1299: ...models REMOVAL AND INSTALLATION The service procedures are the same as those for manual air conditioning except for those parts described below on turbocharged vehicles 4 L Compressor condenser and co...

Page 1300: ...other end of air intake hose B all the way into turbocharger side B AIR PIPE AIR HOSE B INSTALLATION When installing the air hoses make sure that the alignment marks at places indicated by arrows are...

Page 1301: ...3A 171 273 l BRAKE Parking 36 8 l BOOSTER 35 87 l Operating Check 35 64 l DISC 35 93 103 I Front Check 35 70 l Rear Check 35 73 l FLUID LEVEL SENSOR Check 35 64 t HOSES Maintenance 00 52 I LINE 35 91...

Page 1302: ...COOLANT Maintenance 00 51 I Replacement 14 4 l COOLANT TEMPERATURE GAUGE UNIT 14 13 l COOLANT TEMPERATURE SENSOR Engine and Emission Control 17 65 l Engine Cooling 14 l 3 l On vehicle Inspection 13A 9...

Page 1303: ...44 257 l INSTRUMENT PANEL 52A 5 l INTAKE AIR TEMPERATURE SENSOR 17 65 l On vehicle Inspection 13A 88 215 l CHARGE PRESSURE CONTROL SYSTEM Check 15 7 l INTAKE MANIFOLD 15 17 l PLENUM Non Turbo 15 13 l...

Page 1304: ...6 11 54 156 11 54 188 11 37 11 I 378 5 l 54 192 11 54 203 11 Leak Repair Procedure 55 28 l LINE Full Auto A C 55 79 l ManualAJC 55 48 l REGULATOR Door 42 43 l RELEASE CYLINDER Clutch 21 16 l RESISTOR...

Page 1305: ...BELT 11 31 i Maintenance 00 46 I TIRE 31 4 l TRAILING ARM AWD 34 32 l FWD 34 11 l TRANSAXLE T 23 64 l M T AWD 22 19 23 l M T FWD 22 9 l Automatic Maintenance 00 49 l i Manual Maintenance 00 48 I Is CO...

Page 1306: ...6 ALPHABETICAL INDEX Output Voltage Measurement 35 75 l WINDOW GLASS 42 26 l 4 a Door Adjustment 42 12 l Quarter 42 34 l WINDSHIELD 42 29 l WASHER 51 26 l WIPER 51 25 l RJHY506014 1294...

Page 1307: ...1 1 I I I 1 I 1 1 I I I j I i i i I i I j j...

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